SurePOS 500 Series


Hardware Service Guide for Models 545

and 565

SY27-0423-00
SurePOS 500 Series


Hardware Service Guide for Models 545

and 565

SY27-0423-00
 Note
Before using this information and the product it supports, be sure to read “Safety and environmental notices” on page xi and
the general information in Appendix D, “Notices,” on page 125.

First Edition (October 2006)

This edition applies to the IBM® SurePOS Machine Type 4846, Models 545 and 565 and to all subsequent releases
and modifications until otherwise indicated in new editions.
Current versions of Retail Store Solutions documentation are available on the IBM Retail Store Solutions Web site at:
www.ibm.com/solutions/retail/store/support. Click Publications.
Order publications through your IBM representative or the IBM branch office serving your locality. Publications are
not stocked at the address given below.
A form for readers’ comments is also provided at the back of this publication. If this form has been removed, address
your comments to:
IBM Corporation
Retail Store Solutions Information Development
Department ZBDA
P.O. Box 12195
RESEARCH TRIANGLE PARK, NC 27709-9990
U.S.A.
When you send information to IBM, you grant IBM a nonexclusive right to use or distribute the information in any
way it believes appropriate without incurring any obligation to you.
© Copyright International Business Machines Corporation 2006. All rights reserved.
US Government Users Restricted Rights – Use, duplication or disclosure restricted by GSA ADP Schedule Contract
with IBM Corp.
Contents
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety and environmental notices . . . . . . . . . . . . . . . . . xi

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . xi
Environmental notices and statements . . . . . . . . . . . . . . . . xvii
End of life disposal . . . . . . . . . . . . . . . . . . . . . . xvii
Battery disposal . . . . . . . . . . . . . . . . . . . . . . . xvii
Mercury-added statement . . . . . . . . . . . . . . . . . . . xviii
Magnetic stripe reader . . . . . . . . . . . . . . . . . . . . . xviii
Handling static-sensitive devices . . . . . . . . . . . . . . . . . xviii

About this guide . . . . . . . . . . . . . . . . . . . . . . . xix

Who should read this guide . . . . . . . . . . . . . . . . . . . . xix
Related publications . . . . . . . . . . . . . . . . . . . . . . . xix
Publications accessibility . . . . . . . . . . . . . . . . . . . . . xx
Web sites . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
Tell us what you think . . . . . . . . . . . . . . . . . . . . . . xx

Chapter 1. Introducing the IBM SurePOS 500 Series Models 545 and 565 1
Models and features . . . . . . . . . . . . . . . . . . . . . . . 2
Optional features . . . . . . . . . . . . . . . . . . . . . . . 4
Connectors, power, and brightness controls . . . . . . . . . . . . . . . 5
Supported operating systems . . . . . . . . . . . . . . . . . . . . 7
Understanding the display and operating system restrictions . . . . . . . 7
Supported devices . . . . . . . . . . . . . . . . . . . . . . . . 9
System management . . . . . . . . . . . . . . . . . . . . . . . 9
System management programs . . . . . . . . . . . . . . . . . . 9
Remote management . . . . . . . . . . . . . . . . . . . . . 10
Compatible products . . . . . . . . . . . . . . . . . . . . . . . 11
Locating the machine serial number . . . . . . . . . . . . . . . . . 11

Chapter 2. Running diagnostics and troubleshooting . . . . . . . . . 13

Using the CMOS Setup Utility . . . . . . . . . . . . . . . . . . . 13
Using the Main window . . . . . . . . . . . . . . . . . . . . . 13
Restoring the default CMOS settings . . . . . . . . . . . . . . . . 15
Clearing the CMOS settings . . . . . . . . . . . . . . . . . . . 15
Real-time clock and CMOS . . . . . . . . . . . . . . . . . . . 16
Configuring the COM (communication) ports . . . . . . . . . . . . . 16
Using the IBM Diagnostics for POS Systems and Peripherals package . . . . 16
Supported memory keys . . . . . . . . . . . . . . . . . . . . 17
Updating the flash BIOS . . . . . . . . . . . . . . . . . . . . . 17
Power interruption during flash BIOS update procedure . . . . . . . . . 18
Repairing the flash BIOS . . . . . . . . . . . . . . . . . . . . 18
Diagnosing problems and troubleshooting . . . . . . . . . . . . . . . 19
Researching the Knowledgebase . . . . . . . . . . . . . . . . . 19
Preliminary checklist . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting symptoms and actions . . . . . . . . . . . . . . . 20
CMOS recovery . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545
and 565 . . . . . . . . . . . . . . . . . . . . . . . . . . 25

© Copyright IBM Corp. 2006 iii

 Pictorial overview . . . . . . . . . . . . . . . . . . . . . . . . 26
Handling static-sensitive devices . . . . . . . . . . . . . . . . . . 28
Modular servicing and minimum tools . . . . . . . . . . . . . . . 28
Removing the covers . . . . . . . . . . . . . . . . . . . . . . 29
Front (or HDD) cover removal . . . . . . . . . . . . . . . . . . 29
Rear cover removal . . . . . . . . . . . . . . . . . . . . . . 30
Opening the I/O tailgate cover . . . . . . . . . . . . . . . . . . 31
Top cover removal . . . . . . . . . . . . . . . . . . . . . . 32
Hinge cover removal . . . . . . . . . . . . . . . . . . . . . . 33
Display tablet - removing and replacing . . . . . . . . . . . . . . . . 34
Display tablet cable – removing and replacing . . . . . . . . . . . . 35
Front bezel and LCD assembly - removing and replacing . . . . . . . . . 36
Operator card - removing and replacing . . . . . . . . . . . . . . . 38
Tablet hinge assembly – removing and replacing . . . . . . . . . . . . 39
Hard disk drive and bracket – removing and replacing . . . . . . . . . . 40
Hard disk drive fan and bracket – removing and replacing . . . . . . . . . 42
Hard disk drive cables – removing and replacing . . . . . . . . . . . . 43
Cable tie bar – removing and replacing . . . . . . . . . . . . . . . . 44
Power supply – removing and replacing . . . . . . . . . . . . . . . . 45
Power supply latch arm – removing and replacing . . . . . . . . . . . . 46
Rear connector panel (tailgate) – removing and replacing . . . . . . . . . 47
System board – removing and replacing . . . . . . . . . . . . . . . 49
System-board jumper location and settings . . . . . . . . . . . . . 51
System-board battery – removing and replacing . . . . . . . . . . . . 51
Processor fan/heatsink assembly - removing and replacing . . . . . . . 53
Processor module – removing and replacing . . . . . . . . . . . . . 54
Memory modules – removing and replacing . . . . . . . . . . . . . . 55
Memory modules and industry standards . . . . . . . . . . . . . . 56
Base plate – removing and replacing . . . . . . . . . . . . . . . . . 57
Optional features . . . . . . . . . . . . . . . . . . . . . . . . 58
Magnetic stripe reader (MSR) – removing and replacing . . . . . . . . . 58
MSR hole plug – removing and replacing . . . . . . . . . . . . . . 58
PC card blank – removing . . . . . . . . . . . . . . . . . . . . 59
PC card – removing and replacing . . . . . . . . . . . . . . . . . 59
Video adapter card– removing and replacing . . . . . . . . . . . . . 61
Speaker – removing and replacing. . . . . . . . . . . . . . . . . 62
Integrated customer display – removing and replacing . . . . . . . . . 64

Chapter 4. Mounting the SurePOS 500 Models 545 and 565 . . . . . . . 65

Mounting the base plate on a countertop . . . . . . . . . . . . . . . 67
Non-keyboard-integration tray mounting . . . . . . . . . . . . . . . . 70
Countertop with non-keyboard-integration tray mounting . . . . . . . . . 70
Cash drawer . . . . . . . . . . . . . . . . . . . . . . . . . 75
Keyboard-integration tray . . . . . . . . . . . . . . . . . . . . . 80
Countertop and full-size cash drawer . . . . . . . . . . . . . . . . 80
Installing additional peripheral devices . . . . . . . . . . . . . . . . 89
Mounting a distributed customer display and APA display to a cash drawer 89
Installing IBM 4610 SureMark Models TF6 or TF7 printers . . . . . . . . 91

Appendix A. Field replaceable parts . . . . . . . . . . . . . . . . 95

How to use the FRU catalog . . . . . . . . . . . . . . . . . . . . 95
Assembly 1: Models 545 and 565 . . . . . . . . . . . . . . . . . . 96
Assembly 2: Countertop and cash drawer keyboard integration tray and filler
panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Assembly 3: Optional peripherals . . . . . . . . . . . . . . . . . . 100
Assembly 4: Countertop non-keyboard integration tray and filler panels . . . . 102

iv Models 545 and 565 Hardware Service Guide

Assembly 5: Cash drawer non-keyboard integration tray and filler panels 104

Appendix B. Power cords . . . . . . . . . . . . . . . . . . . . 107

Appendix C. System specifications and planning information . . . . . . 109

Physical specifications and dimensions . . . . . . . . . . . . . . . 110
Dimensions with trays . . . . . . . . . . . . . . . . . . . . . 110
Dimensions of unit with 12-inch display . . . . . . . . . . . . . . 113
Dimensions of unit with 15-inch display . . . . . . . . . . . . . . 114
Power requirements and consumption . . . . . . . . . . . . . . . . 115
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Port power ratings . . . . . . . . . . . . . . . . . . . . . . 115
Connector-pin assignments . . . . . . . . . . . . . . . . . . . . 116
External connectors . . . . . . . . . . . . . . . . . . . . . . 116
Temperature, humidity, and altitude limits . . . . . . . . . . . . . . . 124

Appendix D. Notices . . . . . . . . . . . . . . . . . . . . . . 125

Electronic Emission Notices . . . . . . . . . . . . . . . . . . . . 127
Federal Communications Commission (FCC) Statement . . . . . . . . 127
Industry Canada Class A Emission Compliance Statement . . . . . . . 127
Avis de conformité aux normes d’Industrie Canada . . . . . . . . . . 127
European Union (EU) Mark of Conformity Statement . . . . . . . . . 127
Germany . . . . . . . . . . . . . . . . . . . . . . . . . 127
Australia / New Zealand . . . . . . . . . . . . . . . . . . . . 128
Japanese power line harmonics compliance statement . . . . . . . . . . 128
Japanese Voluntary Control Council for Interference (VCCI) Statement . . . . 128
Korean Communications Statement . . . . . . . . . . . . . . . . . 129
Chinese Class A warning statement . . . . . . . . . . . . . . . . . 129
Taiwanese Class A Warning Statement . . . . . . . . . . . . . . . 129
Taiwan contact information . . . . . . . . . . . . . . . . . . . 129
Taiwan recycle statement . . . . . . . . . . . . . . . . . . . 130
Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . 130
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . 130

Appendix E. Safety information . . . . . . . . . . . . . . . . . 133

Safety Information-English . . . . . . . . . . . . . . . . . . . . 133
Safety Information-Arabic . . . . . . . . . . . . . . . . . . . . 135
Safety Information-Brazilian Portuguese . . . . . . . . . . . . . . . 137
Safety Information-French . . . . . . . . . . . . . . . . . . . . 139
Safety Information-Hebrew . . . . . . . . . . . . . . . . . . . . 142
Safety Information-Korean . . . . . . . . . . . . . . . . . . . . 144
Safety Information-Italian . . . . . . . . . . . . . . . . . . . . . 147
Safety Information-Spanish . . . . . . . . . . . . . . . . . . . . 150
Safety Information-German . . . . . . . . . . . . . . . . . . . . 152
Safety Information-Traditional Chinese . . . . . . . . . . . . . . . . 154

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Part number index. . . . . . . . . . . . . . . . . . . . . . . 169

Contents v
vi Models 545 and 565 Hardware Service Guide
Figures
1. IBM SurePOS 500 Series configuration with optional features . . . . . . . . . . . . . . . 1
2. Tablet connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Rear view of input/output available on all models . . . . . . . . . . . . . . . . . . . 6
4. Serial number location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. CMOS Setup Utility main window . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. CMOS reset jumper J25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. Pictorial overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8. Unlatching the front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9. Removing the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10. Opening the I/O tailgate cover . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11. Locating the top cover release latch . . . . . . . . . . . . . . . . . . . . . . . . 32
12. Removing the hinge cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13. Removing the display tablet . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14. Removing the display tablet cable from the system board . . . . . . . . . . . . . . . . 35
15. Disconnecting the touch cable and removing the front bezel . . . . . . . . . . . . . . . 36
16. View of L-shaped keyways . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
17. Removing the operator card . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
18. Removing the tablet hinge assembly . . . . . . . . . . . . . . . . . . . . . . . 39
19. HDD installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
20. Removing the hard disk drive and bracket . . . . . . . . . . . . . . . . . . . . . 41
21. Removing the HDD fan and bracket . . . . . . . . . . . . . . . . . . . . . . . . 42
22. Removing the cable tie bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
23. Removing the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
24. Removing the power supply latch arm . . . . . . . . . . . . . . . . . . . . . . . 46
25. Opening the I/O tailgate cover . . . . . . . . . . . . . . . . . . . . . . . . . . 47
26. Removing the tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27. Removing the system board . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
28. System board jumper location . . . . . . . . . . . . . . . . . . . . . . . . . . 51
29. System-board battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
30. Removing the processor fan/ heatsink assembly . . . . . . . . . . . . . . . . . . . 53
31. Memory socket location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
32. Memory module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
33. Removing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
34. Removing the MSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
35. Removing the PC card adapter slot blank . . . . . . . . . . . . . . . . . . . . . . 59
36. Removing a PC card adapter . . . . . . . . . . . . . . . . . . . . . . . . . . 60
37. Video adapter card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
38. Removing the speaker thumbscrew . . . . . . . . . . . . . . . . . . . . . . . . 62
39. Removing the speaker and speaker EMC shield . . . . . . . . . . . . . . . . . . . 63
40. Removing the integrated display . . . . . . . . . . . . . . . . . . . . . . . . . 64
41. Base plate countertop dimensions . . . . . . . . . . . . . . . . . . . . . . . . 68
42. Attaching the base foot to the countertop . . . . . . . . . . . . . . . . . . . . . . 69
43. Countertop with non-keyboard-integration tray mounting . . . . . . . . . . . . . . . . 70
44. Countertop integration tray pattern with display and countertop cutout on right side . . . . . . 71
45. Detaching the fence from the tray. . . . . . . . . . . . . . . . . . . . . . . . . 71
46. Sliding the fence off of the integration tray . . . . . . . . . . . . . . . . . . . . . 72
47. Overview of integration tray, SurePOS 500, printer, and filler panels . . . . . . . . . . . . 73
48. Connecting filler panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
49. Attaching the integration tray to cash drawer . . . . . . . . . . . . . . . . . . . . 75
50. Attaching a mounting plate to center of cash-drawer integration tray . . . . . . . . . . . . 76
51. Attaching mounting plate to the cash drawer integration tray . . . . . . . . . . . . . . . 77
52. Attaching filler panels and the rear modesty cover . . . . . . . . . . . . . . . . . . 79
53. Full-size keyboard-integration tray on a countertop . . . . . . . . . . . . . . . . . . 80
© Copyright IBM Corp. 2006 vii
54. Countertop keyboard-integration tray assembly . . . . . . . . . . . . . . . . . . . . 82
55. Installing the keyboard-integration tray on a cash drawer . . . . . . . . . . . . . . . . 83
56. Installing the SurePOS 500 onto the integration tray . . . . . . . . . . . . . . . . . . 84
57. Installing the 4610 printer onto the integration tray . . . . . . . . . . . . . . . . . . 85
58. Installing the keyboard onto the integration tray . . . . . . . . . . . . . . . . . . . 86
59. Attaching the distributed customer display cable . . . . . . . . . . . . . . . . . . . 86
60. Installing the distributed customer display onto the integration tray . . . . . . . . . . . . 87
61. Attaching the distributed customer display cable . . . . . . . . . . . . . . . . . . . 89
62. Attaching the distributed customer display to the system unit. . . . . . . . . . . . . . . 90
63. Installing the distributed customer display onto the keyboard integration tray . . . . . . . . . 91
64. 4610 TF6 or TF7 printer connector locations . . . . . . . . . . . . . . . . . . . . . 92
65. Attaching and routing the cables to the printer. . . . . . . . . . . . . . . . . . . . . 93
66. Attaching the 4610 TF6 or TF7 printer mounting plate for a non-keyboard integration tray . . . . 93
67. 4610 TF6 or TF7 cable routing . . . . . . . . . . . . . . . . . . . . . . . . . . 94
68. Dimensions of SurePOS Models 545 and 565 with retail tray . . . . . . . . . . . . . . 111
69. Dimensions of SurePOS Models 545 and 565 with counter top tray . . . . . . . . . . . . 111
70. SurePOS Models 545 and 565 with cash drawer tray . . . . . . . . . . . . . . . . . 112
71. Dimensions of unit with 12-inch display . . . . . . . . . . . . . . . . . . . . . . 113
72. Dimensions of unit with 15-inch display . . . . . . . . . . . . . . . . . . . . . . 114

viii Models 545 and 565 Hardware Service Guide

Tables
1. Models 545 and 565 summary . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. E and P Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Controls and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Rear connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. SurePOS 500 Models 545 and 565 supported operating systems . . . . . . . . . . . . . 7
7. Operating system with display combinations and restrictions . . . . . . . . . . . . . . . 8
8. Supported video resolutions in Windows operating system . . . . . . . . . . . . . . . . 8
9. Summary of tested and supported devices . . . . . . . . . . . . . . . . . . . . . . 9
10. SurePOS 500 task information . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11. Symptoms and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12. Pictorial overview of common removal tasks . . . . . . . . . . . . . . . . . . . . . 26
13. Service personnel tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14. System board jumper settings . . . . . . . . . . . . . . . . . . . . . . . . . . 51
15. Mounting configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
16. Countertop integration tray legend . . . . . . . . . . . . . . . . . . . . . . . . 73
17. Countertop integration tray legend . . . . . . . . . . . . . . . . . . . . . . . . 82
18. 4610 SureMark printer on a full-size keyboard-integration tray legend . . . . . . . . . . . 85
19. Power cord lengths and part numbers by country . . . . . . . . . . . . . . . . . . 107
20. Height, weight and depth of the SurePOS 500 Models 545 and 565 . . . . . . . . . . . 110
21. Weights of integrated, distributed displays and MSR . . . . . . . . . . . . . . . . . 110
22. SurePOS 500 Models 545 and 565 dimensions . . . . . . . . . . . . . . . . . . . 110
23. Input voltage, frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
24. SurePOS 500 Series Models 545 and 565 power supply . . . . . . . . . . . . . . . . 115
25. Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
26. Port current ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
27. Speaker connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . . 116
28. MSR connector-pin assignments. . . . . . . . . . . . . . . . . . . . . . . . . 116
29. USB port connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . . 118
30. USB port connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . . 118
31. Keyboard and mouse connector-pin assignments . . . . . . . . . . . . . . . . . . 119
32. Keyboard and mouse connector-pin assignments . . . . . . . . . . . . . . . . . . 119
33. Microphone connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . 119
34. Headphone connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . 119
35. RJ-45 connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . . . 120
36. Assignments for 15-pin serial connector . . . . . . . . . . . . . . . . . . . . . . 121
37. Ethernet connector-pin assignments . . . . . . . . . . . . . . . . . . . . . . . 121
38. Assignment of external-video connector pins . . . . . . . . . . . . . . . . . . . . 122
39. Assignment of cash drawer connector pins . . . . . . . . . . . . . . . . . . . . . 123
40. Assignment of integrated customer-display connector pins . . . . . . . . . . . . . . . 123
41. Temperature, humidity, altitude limits . . . . . . . . . . . . . . . . . . . . . . . 124

© Copyright IBM Corp. 2006 ix

x Models 545 and 565 Hardware Service Guide
Safety and environmental notices
Safety notices are printed throughout this book.

A danger notice indicates the presence of a hazard that has the potential of causing
death or serious personal injury.

A caution notice indicates the presence of a hazard that has the potential of causing
moderate or minor personal injury.

An attention notice indicates the possibility of damage to a program, device,

system, or data.

A note provides important tips, guidance, or advice.

Safety Information

Danger:
Before you begin to install this product, read the safety information in IBM
Safety Information - Read This First, GA27–4004. This booklet describes safe
procedures for cabling and plugging in electrical equipment.

Gevaar:
Voordat u begint met de installatie van dit produkt, moet u eerst de
veiligheidsinstructies lezen in de brochure Veiligheidsinstructies—Lees dit
eerst, GA27–4004. Hierin wordt beschreven hoe u electrische apparatuur op
een veilige manier moet bekabelen en aansluiten.

Perigo:
Antes de começar a instalar este produto, leia as informações de segurança
contidas em Informações Sobre Seguranaça—Leia Isto Primeiro, GA27–4004.
Esse folheto descreve procedimentos de segurança para a instalação de
cabos e conexões em equipamentos elétricos.

© Copyright IBM Corp. 2006 xi

 Fare!
Før du installerer dette produkt, skal du læse sikkerhedsforskrifterne i
Sikkerhedsforskrifter—Lœs dette først GA27–4004. Vejledningen beskriver den
fremgangsmåde, du skal bruge ved tilslutning af kabler og udstyr.

Gevaar
Voordat u begint met het installeren van dit produkt, dient u eerst de
veiligheidsrichtlijnen te lezen die zijn vermeld in de publikatie IBM Safety
Information — Read This First, GA27–4004. In dit boekje vindt u veilige
procedures voor het aansluiten van elektrische appratuur.

VAARA
Ennen kuin aloitat tämän tuotteen asennuksen, lue julkaisussa
Turvaohjeet—Luetämä ensin, GA27–4004, olevat turvaohjeet. Tässä
kirjasessa on ohjeet siitä, miten sähkölaitteet kaapeloidaan ja kytketään
turvallisesti.

Danger
Avant d’installer le présent produit, consultez le livret Informations pour la
sécurité–Lisez-moi d’abord, GA27–4004, qui décrit les procédures à respecter
pour effectuer les opérations de câblage et brancher les équipements
électriques en toute sécurité.

xii Models 545 and 565 Hardware Service Guide

 Vorsicht
Bevor mit der Installation des Produktes begonnen wird, die
Sicherheitshinweise in Sicherheitsinformationen—Bitte zuerst lesen, IBM Form
GA27–4004. Diese Veröffentlichung beschreibt die Sicherheitsvorkehrungen
für das Verkabeln und Anschlieβen elektrischer Geräte.

Vigyázat
Mielôtt megkezdi a berendezés üzembe helyezését, olvassa el a IBM Safety
Information — Read This First, GA27–4004 könyvecskében leírt biztonsági
információkat. Ez a könyv leírja, milyen biztonsági intézkedéseket kell
megtenni az elektromos berendezés huzalozásakor illetve csatlakoztatásakor.

Pericolo
prima di iniziare l’installazione di questo prodotto, leggere le informazioni
relative alla sicurezza riportate nell’opuscolo Informazioni di sicurezza—Prime
informazioni da leggere in cui sono descritte le procedure per il cablaggio ed il
collegamento di apparecchiature elettriche.

Fare
Før du begynner å installere dette produktet, må du lese
sikkerhetsinformasjonen i Sikkerhetsinformasjon—Les dette først, GA27–4004
som beskriver sikkerhetsrutinene for kabling og tilkobling av elektrisk utstyr.

Safety and environmental notices xiii

 Perigo
Antes de iniciar a instalação deste produto, leia as informações de segurança
Informações de Segurança—Leia Primeiro, GA27–4004. Este documento
descreve como efectuar, de um modo seguro, as ligações eléctricas dos
equipamentos.

Peligro
Antes de empezar a instalar este producto, lea la información de seguridad en
Información de Seguridad—Lea Esto Primero, GA27–4004. Este documento
describe los procedimientos de sequridad para cablear y enchufar equipos
eléctricos.

Varning—livsfara
Innan du börjar installera den här produkten bör du läsa
säkerhetsinformationen i dikumentet Säkerhetsföreskrifter—Läs detta först,
GA27–4004. Där beskrivs hur du på ett säkert sätt ansluter elektrisk
utrustning.

xiv Models 545 and 565 Hardware Service Guide

IBM

IBM

GA27-4004

GA27-4004

Safety and environmental notices xv

 GA27-4004

IBM GA27-4004

GA27-4004

GA27-4004

GA27-4004

GA27-4004

xvi Models 545 and 565 Hardware Service Guide

Environmental notices and statements
This section covers product recycling and product disposal.

End of life disposal

This unit must be recycled or discarded according to applicable local and national
regulations. IBM encourages owners of information technology (IT) equipment to
responsibly recycle their equipment when it is no longer needed. IBM offers a
variety of product return programs and services in several countries to assist
equipment owners in recycling their IT products. Information on IBM product
recycling offerings can be found on IBM’s Internet site at http://www.ibm.com/ibm/
environment/products/prp.shtml.

Notice: This mark applies only to countries within the European Union (EU) and
Norway.

Appliances are labeled in accordance with European Directive 2002/96/EC

concerning waste electrical and electronic equipment (WEEE). The Directive
determines the framework for the return and recycling of used appliances as
applicable throughout the European Union. This label is applied to various products
to indicate that the product is not to be thrown away, but rather reclaimed upon end
of life per this Directive.

In accordance with the European WEEE Directive, electrical and electronic

equipment (EEE) is to be collected separately and to be reused, recycled, or
recovered at end of life. Users of EEE with the WEEE marking per Annex IV of the
WEEE Directive, as shown above, must not dispose of end of life EEE as unsorted
municipal waste, but use the collection framework available to customers for the
return, recycling, and recovery of WEEE. Customer participation is important to
minimize any potential effects of EEE on the environment and human health due to
the potential presence of hazardous substances in EEE. For proper collection and
treatment, contact your local IBM representative.

Disposal of IT products should be in accordance with local ordinances and

regulations.

Battery disposal
This unit contains batteries. Remove and discard these batteries, or recycle them,
according to local regulations. Return IBM units as determined by service
procedures.

Taiwanese battery recycling statement

Waste batteries, please recycle.

Safety and environmental notices xvii

Mercury-added statement
The fluorescent lamp in the liquid crystal display contains mercury. Dispose of it as
required by local ordinances and regulations.

Magnetic stripe reader

The electronic article surveillance device (EAS) that deactivates security tags
should not be closer than 18 in. (46 cm.) to the nearest edge of the magnetic stripe
reader (MSR).

Handling static-sensitive devices

Attention: Static electricity can damage electronic devices and your system. To
avoid damage, keep static-sensitive devices in their static protective bags until you
are ready to install them.

To reduce the possibility of electrostatic discharge, observe the following

precautions:
v Limit your movement. Movement can cause static electricity to build up around
you.
v Handle the device carefully, holding it by its edges or its frame.
v Do not touch solder joints, pins, or exposed printed circuitry.
v Do not leave the device where others can handle and possibly damage the
device.
v While the device is still in its anti-static bag, touch it to an unpainted metal part of
the system unit for at least 2 seconds. (This action removes static electricity from
the package and from your body.)
v Remove the device from its package and install it directly into your system,
without putting it down. If it is necessary to put the device down, place it onto its
static-protective bag. (If your device is an adapter, place it component side up.)
Do not place the device onto the cover of the system or onto a metal table.
v Take additional care when handling devices during cold weather because heating
reduces indoor humidity and increases static electricity.

xviii Models 545 and 565 Hardware Service Guide

About this guide
This guide provides information necessary to repair and maintain the IBM
SurePOS® 500 Series Machine Type 4846, Models 545 and 565.

Who should read this guide

This guide is for the IBM service representative to assist in maintaining and
repairing the IBM SurePOS 500 Series Models 545 and 565.

Related publications
The SurePOS 500 Series library consists of the following publications:
v IBM SurePOS 500 Series Planning, Installation, and Operation Guide for Models
545 and 565, GA27-4330
This guide provides installation and setup information, including option installation
procedures and problem determination information.
v IBM SurePOS 500 Series Operating System Installation Guide for Models 545
and 565, GA30-4132
This guide provides step-by-step information on installing the operating software
for the product.
v IBM Point of Sale Options and I/O Devices Service Guide, GC30-9737
This guide describes the problem-determination and repair procedures for cash
drawers, displays, keyboards, and options that are attached to IBM® SurePOS™
systems.
v IBM Safety Information — Read This First, GA27-4004
This document contains important safety information.

© Copyright IBM Corp. 2006 xix

 To access these publications:
1. Go to: www.ibm.com/solutions/retail/store/.
2. Select Support, then select Publications.

Publications accessibility
The soft-copy version of this guide and other related publications are
accessibility-enabled.

Web sites
For the latest troubleshooting guidance and symptom-fix tip information, go to the
IBM support Web site at: www.ibm.com/solutions/retail/store. Select
Knowledgebase.

This site contains additional information that is gathered from field experience, and
not available when this document was developed.

Tell us what you think

Your feedback is important in helping us provide accurate and high-quality
information. Please take a few moments to tell us what you think about this
document.

You can use either of these ways to provide feedback:

v Visit our Web site at http://www.ibm.com/solutions/retail/store. Select Support,
then Publications. Select the publication comments link within the introductory
text. Fill in the requested information and your comments. Be sure to include the
name and form number of the document in the Publication ID field.
v Print and fill out the form at the end of this document. Return the form to us by
mail or by giving it to an IBM representative.

If applicable, include a reference to the specific location of the text (for example, the
page or table number) on which you are commenting.

Between major revisions of this document, we might make minor technical updates.
The latest version of this document is available on the Retail Store Solutions Web
site at www.ibm.com/solutions/retail/store/support/publications.

xx Models 545 and 565 Hardware Service Guide

Chapter 1. Introducing the IBM SurePOS 500 Series Models
545 and 565
Models and features . . . . . . . . . . . . . . . . . . . .
. 2 . .
Optional features . . . . . . . . . . . . . . . . . . . .
. 4 . .
Connectors, power, and brightness controls . . . . . . . . . . . .
. 5 . .
Supported operating systems . . . . . . . . . . . . . . . . .
. 7 . .
Understanding the display and operating system restrictions . . . .
. 7 . .
Supported devices . . . . . . . . . . . . . . . . . . . . .
. 9 . .
System management . . . . . . . . . . . . . . . . . . . .
. 9 . .
System management programs . . . . . . . . . . . . . . .
. 9 . .
Remote management . . . . . . . . . . . . . . . . . . . . . 10
Compatible products . . . . . . . . . . . . . . . . . . . . . . . 11
Locating the machine serial number . . . . . . . . . . . . . . . . . 11

The IBM SurePOS 500 Series Models 545 and 565 (machine type 4846) enable
you to provide fast, accurate customer service and to manage your restaurant or
store efficiently. You can configure the SurePOS 500 Series systems to support a
wide variety of both IBM and non-IBM input/output (I/O) devices – everything from
standard serial-attached devices to the Universal Serial Bus (USB)-attached
devices.

System resources and the operating system may limit the use of ports. Figure 1
shows a sample SurePOS 500 configuration.

IBM 4820 display

2x20 or 160x40 VFD

Standard Keyboard

Integrated
External display VFD

IBM 4610 SureMark printer Magnetic Stripe reader

RS-232

IBM cash drawer

External diskette drive

RS-232 Mouse

Check reader

12v and 24v USB Devices

powered
USB devices

Figure 1. IBM SurePOS 500 Series configuration with optional features. Note: The location of
the peripherals in this diagram is not an indication of the actual connector location.

© Copyright IBM Corp. 2006 1

Introducing the SurePOS 500 Models 545 and 565

Models and features

Table 1 and Table 2 on page 3summarizes the SurePOS 500 models and features.
Table 1. Models 545 and 565 summary
Attribute Model 545 Model 565
Processor and FSB speed Intel 326 Celeron D 2.53GHz / 533MHz
Chipset Intel 915GV/ICH6
BIOS AwardBIOS
Main memory 512 MB (standard) to 1 GB DDR2 DIMMs
2 slots (2 GB max)
Video Integrated 2D/3D Intel graphics controller for LCD/CRT
Dual independent video option for CRT with dual video card
LCD
One of the following:
800x600 12.1 in TFT, High Bright
1024x768 15-in TFT (2 bulb)
Touch IBM enhanced Infra-red
Audio AC97 compliant, Codec; amplified stereo
Not available
speakers
Mass storage 80 GB SATA II
LAN Auto sensing 10BaseT/100 BaseTx Ethernet support
Expansion PC-Card slot (accommodates PC cards up
Not available
to 119 mm long.)
I/O ports and connectors 7 standard USB (3 display tablet, 4 tower rear)
Mouse (rear)
Keyboard (rear)
1, 12V powered USB (rear)
1, 24V powered USB (rear)
2 cash drawer
3 unpowered RS-232
1 powered RS-232 (external customer display)
Head phone (available on Model 565)
Microphone (available on Model 565)
RJ-45 Ethernet LAN
External CRT
External floppy (USB)
MSR (3-track/JUCC)
I/O devices Integrated 2x20
Distributed 2x20
Distributed APA
Power
HDD activity
Indicators Ethernet

See Table 3 on page 3 for the status indicator states.

Power
Controls LCD brightness
Volume (with speaker kit, available on Model 565)

2 Models 545 and 565 Hardware Service Guide

 Introducing the SurePOS 500 Models 545 and 565

Table 2. E and P Models

Model Number Description
4846-E45 System unit Model 545, preloaded with the Windows XP
Embedded for Point of Service (WEPOS)
4846-E65 System unit Model 565, preloaded with the Windows XP
Embedded for Point of Service (WEPOS)
4846-P45 System unit Model 545 with 4610 Printer
4846-P65 System unit Model 565 with 4610 Printer

Table 3. Status indicators

Status/power indicator On: Logic working correctly. Source AC

power present and within tolerance.
Off: System board defective or power is
off
Blinking during Logic malfunction or system in
POST: suspend mode

HDD indicator On HDD is reading or writing

Off: No HDD activity
Blinking: HDD is reading or writing

Ethernet Green Left LED states:

v Off - 10 Mb mode
v On - 100 Mbit
Right LED states
v Off - No link
v On - Good link
v Blinking - Network activity

Chapter 1. Introducing the IBM SurePOS 500 Series Models 545 and 565 3
Introducing the SurePOS 500 Models 545 and 565

Optional features
The following is a list of optional features available for the SurePOS 500:
v Memory:
– 512 MB DDR2 (standard)
– 1 GB DDR2
v Displays:
– Integrated 2x20
– Distributed 2x20
– Distributed APA
– 12-in LCD
v MSR:
– 3-track
– JUCC
v Countertop/full-size cash drawer integration tray for printer and keyboard
v Countertop integration tray for single station printer, non-keyboard
v Wide cash drawer integration kit for single station printer, non-keyboard
v Cash drawer
v Compact A/N POS KEYBOARD
v External USB floppy drive
v USB antenna cover (accommodates USB antennas up to 32mm X 101 mm;
excluding the exposed connector)
v Side cover to accommodate PC Card antennas with lengths up to 119 mm

4 Models 545 and 565 Hardware Service Guide

 Introducing the SurePOS 500 Models 545 and 565

Connectors, power, and brightness controls

Figure 2 and Table 4 identifies the controls and tablet connectors.

A B C D

I H G F E

Figure 2. Tablet connectors

Table 4. Controls and connectors

Reference Description

A MSR port

B
C
F USB connectors

D Tablet cable connector

E Touch cable connector (located behind door)

G
H LCD brightness controls (minus – and plus +)

I Power button

Figure 3 on page 6 and Table 5 on page 6 identifies the rear connectors.

Chapter 1. Introducing the IBM SurePOS 500 Series Models 545 and 565 5
Introducing the SurePOS 500 Models 545 and 565

J K L M N

A B C
D

24v 12v
3A 3B Ethernet
D B
F E
C A

O P Q R S T
Figure 3. Rear view of input/output available on all models

Table 5. Rear connectors

Reference Description Icon

J Serial ports (3), non-powered

K 12V serial

L VGA

M Keyboard

N Mouse

O, P Cash drawer connectors (2 each 3A, 3B

rated 24 V, 25 mA continuous)

Q Ethernet

R Powered 24V rated for 3A continuous

S Powered 12V

T USB 2.0 ports (4)

6 Models 545 and 565 Hardware Service Guide

 Introducing the SurePOS 500 Models 545 and 565

Supported operating systems

Table 6 describes the operating system support:
Table 6. SurePOS 500 Models 545 and 565 supported operating systems
Support for Point of Sale
application drivers (MSRs,
customer displays, cash drawers,
Supported operating system tone) Application Driver Notes
PC DOS 2000 Hardware direct interface only
Windows 2000, XP IBM UPOS Drivers for Windows,
Windows Embedded Version 1.9.2 or later. (Includes
Point of Service (WEPOS) JavaPOS drivers for Windows and
Power management via ACPI OPOS drivers.) Driver updates are required from
Notes: previous SurePOS 500 models. MSR
and Scanner in Wedge mode is not
1. Only DOS full screen mode
supported.
supported due to touch screen
alignment requirements.
2. Windows DBCS versions
(Japanese/Korean/Chinese)
supported.

Understanding the display and operating system restrictions

The operating system, the display size, and any attached CRTs can affect the
display resolution. The following definitions describe the terms and various display
configurations:
Single A type of display configuration that supports only one display device.
Twin A type of display configuration that supports two display devices, each of
which has the same content, resolution, and timings. Also referred to as
Simultaneous mode.
Clone A type of display configuration that drives two display devices, each
displaying the same content, but can have different resolutions and
(independent) timings.
Dual Independent Head (DIH)
A type of display configuration that supports two displays with different
content on each display device. Also referred to as an Extended Desktop.

The onboard LCD supports the following modes when using the indicated operating
system:
v DOS: Single
v Windows 2000 and Windows XP: Clone (default), twin
v WEPOS: Clone (default), twin

The onboard LCD and one extra attached LCD:

v DOS: Single; the onboard LCD is primary
v Windows 2000 and Windows XP: Clone (default), twin, DIH
v WEPOS: Clone (default), twin, DIH

Table 7 on page 8 summarizes the restrictions, if any, imposed by the operating

system.

Chapter 1. Introducing the IBM SurePOS 500 Series Models 545 and 565 7
Introducing the SurePOS 500 Models 545 and 565

Table 7. Operating system with display combinations and restrictions

Display DOS Windows
Image Single₁ Single
Onboard LCD only
Restrictions None

Onboard LCD + Image Single Dual-same

external display
Restrictions External display not Media clips show on
supported onboard LCD only;
External display must
be the same resolution
as onboard LCD

Image Single, on board LCD Dual-independent₂

Onboard LCD + Restrictions None Onboard LCD

Add-in video card becomes secondary
display when installing
Windows

Restrictions Touch on primary None

General
display only

1. Dual-same: same data on both displays; simultaneous mode

2. Dual-independent; different/independent data on both displays; extended
desktop
Table 8. Supported video resolutions in Windows operating system
LCD size Available video resolutions for onboard LCD
12 in. 640 x 480, 720 x 480, 800 x 600
15 in. 640 x 480, 720 x 480, 800 x 600,
960 x 540, 1024 x 768

8 Models 545 and 565 Hardware Service Guide

 Introducing the SurePOS 500 Models 545 and 565

Supported devices
Table 9 summarizes the industry standard devices that have been tested with the
product. Other industry devices may be supported using standard interfaces;
however, no testing was performed to insure functionality in all aspects of operation.
Table 9. Summary of tested and supported devices
Port type Supported device Hot plug support (See note 1)
RS-232 (Serial) v 4610 TF6/TF7 single station Not supported
thermal printer
v 4610-TG3, TG4, TG5
CRT (Video) v 4820-4FD/4FT with MSR option, Not supported
USB
v 4820 - 1GD, 2GN, 2GD, 2GB
USB v 4610-GB3 Yes; however, USB not supported on
DOS; powered USB ports is not
v 4610-TG3/TG4/TG5
supported.
v IBM USB floppy drive
v IBM USB keyboard
v IBM Memory key
v IBM 4685-S01/L0h handheld
scanner
Keyboard/Mouse v IBM PS/2 keyboard Yes for USB devices
No for PS/2 devices
v IBM mouse
v Compact retail A/N keyboard (See
note 2.)
PC Card v See the IBM web site Yes
(www.ibm.com/solutions/retail/
store/) for tested devices.
Headphone/microphone v IBM or equivalent Yes

Notes:
1. Assumes device natively supports hot plugging and can be hot plugged with any operating system.
2. CANPOS MSR option is mutually exclusive for SurePOS 500 Models 545 and 565.
3. Some PCMCIA devices may require third party software support.

System management
This section describes the types of system management available with the
SurePOS 500.

System management programs

The SurePOS 500 Series supports the following system and power management
programs:
Desktop Management Interface
The SurePOS 500 Series supports System Management BIOS (SMBIOS)
v2.4, supporting a DMI-compliant agent such as Tivoli®. This allows access
to low-level information. Examples of information that can be accessed are
the BIOS level, processor type, speed, manufacturer, system-board
information, and detailed memory information.

Chapter 1. Introducing the IBM SurePOS 500 Series Models 545 and 565 9
Introducing the SurePOS 500 Models 545 and 565

RDM (Remote Deployment Manager) and IBM Director.

RDM can install an OS and update BIOS remotely and probe machines for
low-level information. IBM Director can remotely configure applications and
operating systems, transfer files, and inventory workstations on a network.
APM APM consists of several layers of software that allow the operating system,
applications, and BIOS to work together to reduce power consumption.
APM is supported on DOS and Linux platforms.
Advanced Configuration and Power Interface
Advanced Configuration and Power Interface (ACPI) V1.0 defines a
hardware and software interface and tables by which the operating system
can alter the characteristics of the hardware-specific devices. ACPI is
supported on Windows 2000 and Windows XP.
Power up on LAN
This feature enables the system to power on when it receives a specific
frame over the local area network (LAN) through the 10/100-Mbps Ethernet
feature. You can enable power up (wake) on LAN by enabling Wake on
LAN in the CMOS Setup Utility program.
Power up (wake) on daily alarm
This feature enables the system to turn on at the same time every day. You
can enable power up (wake) on daily alarm by enabling Wake on Alarm in
the CMOS Setup Utility program.
RMA IBM Remote Management Agent is a component of IBM Store Integration
Framework that simplifies the delivery of new consumer-facing devices in
stores to support the delivery of superior service. For more information, see
the Retail Store Solutions web site.

Remote management
The SurePOS 500 Models 545 and 565 supports remote system management over
the network. The following functions are supported:
v Selectable startup sequence
v Update POST/BIOS from the network
v Ethernet
v Power up (wake) on LAN

10 Models 545 and 565 Hardware Service Guide

 Introducing the SurePOS 500 Models 545 and 565

Compatible products
You can use the following products with the SurePOS 500:
v 4610 SureMark Single Station Thermal Printer (RS-232 models)
v 4610 SureMark Printer
v 4820 SurePoint Solution Terminal
v IBM point-of-sale USB devices
v Original equipment manufacturer (OEM) USB devices
v OEM RS-232 Point of Sale devices (printers, 2x20, and others)
v OEM USB printers
v CRT/LCD displays
v IBM USB portable CD-ROM drive
v IBM USB 2.0 CD-RW/DVD-ROM drive
v TEAC USB CD-ROM drive

Locating the machine serial number

The serial number and model number (
A in Figure 4) are located under the front
cover/HDD cover.
B points to the tablet size label.

B
Figure 4. Serial number location

Chapter 1. Introducing the IBM SurePOS 500 Series Models 545 and 565 11
12 Models 545 and 565 Hardware Service Guide
Chapter 2. Running diagnostics and troubleshooting
Using the CMOS Setup Utility . . . . . . . . . . . . . . . . . . . 13
Using the Main window . . . . . . . . . . . . . . . . . . . . . 13
Standard CMOS features . . . . . . . . . . . . . . . . . . . 14
Advanced BIOS Features . . . . . . . . . . . . . . . . . . . 14
Integrated peripherals . . . . . . . . . . . . . . . . . . . . 14
Power Management . . . . . . . . . . . . . . . . . . . . . 14
PnP/PCI Configurations . . . . . . . . . . . . . . . . . . . . 14
PC Health Status . . . . . . . . . . . . . . . . . . . . . . 15
Load Defaults . . . . . . . . . . . . . . . . . . . . . . . 15
Set Password . . . . . . . . . . . . . . . . . . . . . . . 15
Restoring the default CMOS settings . . . . . . . . . . . . . . . . 15
Clearing the CMOS settings . . . . . . . . . . . . . . . . . . . 15
Real-time clock and CMOS . . . . . . . . . . . . . . . . . . . 16
Configuring the COM (communication) ports . . . . . . . . . . . . . 16
Using the IBM Diagnostics for POS Systems and Peripherals package . . . . 16
Supported memory keys . . . . . . . . . . . . . . . . . . . . 17
Updating the flash BIOS . . . . . . . . . . . . . . . . . . . . . 17
Power interruption during flash BIOS update procedure . . . . . . . . . 18
Repairing the flash BIOS . . . . . . . . . . . . . . . . . . . . 18
Diagnosing problems and troubleshooting . . . . . . . . . . . . . . . 19
Researching the Knowledgebase . . . . . . . . . . . . . . . . . 19
Preliminary checklist . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting symptoms and actions . . . . . . . . . . . . . . . 20
CMOS recovery . . . . . . . . . . . . . . . . . . . . . . . . 23

Using the CMOS Setup Utility

Follow these steps to start the CMOS Setup Utility:
1. Switch the power ON.
2. Press Del during POST when prompted, or tap the touch screen two times.
Use the keys listed in the legend bar at the bottom of the screen to make your
selections or exit from the current menu. The help window on the right side of
each menu displays the online help information for the currently selected item.

Figure 5 on page 14 is an example of the initial panel that is displayed in the CMOS
Setup Utility.

Using the Main window

Use the Main window (Figure 5 on page 14) to access the various features of the
CMOS utility. The navigation tool bar is located at the bottom of the screen.

© Copyright IBM Corp. 2006 13

 Figure 5. CMOS Setup Utility main window

Standard CMOS features

This menu provides basic functions, like setting the time and date. It also provides
basic information, such as BIOS version, Ethernet MAC address, memory size, and
machine serial number.

To change the date, month, and time using the CMOS Utility,
1. With the month entry highlighted (in red), touch the red numeric keyboard to
indicate the current month. For example, enter 8 to change the month to Aug.
2. Touch enter. The correct month appears as text.
3. Using the displayed keyboard, enter the number of the month. For example,
enter 8 for August, or 1 for January, and select Enter.

Advanced BIOS Features

The Advanced BIOS window allows you to modify the POST and boot device
settings, and set the keyboard features.

Integrated peripherals
Using this menu you can configure I/O devices, such as serial ports, Ethernet,
parallel port, USB controller, and keyboard.

Power Management
Use the Power Management window to configure Wake on Ring, the power
savings, hard disk time-out, video time-out, and other power settings.

Wake on Ring: Use the Power Management Setup menu to enable the Wake on
Ring feature. Wake on Ring allows a modem attached to Serial Port D to wake the
system using Ring Indicate. Additionally, the tailgate card contains jumpers for
ports A-C to optionally associate DSR (pin 1) to Ring Indicate.

PnP/PCI Configurations
This option allows advanced functions for PCI configuration data.

14 Models 545 and 565 Hardware Service Guide

 PC Health Status
This is an information window that provides the CPU and system temperatures,
voltages on the system board, and fan speed.

Load Defaults
This selection resets all options to their default configuration.

Set Password
Use the password options menu to set, change, or clear the system password.

Restoring the default CMOS settings

To restore CMOS default settings, select Load Optimized Settings from the main
menu.

Clearing the CMOS settings

The SurePOS 500 uses battery-backed CMOS memory to store system settings. If
the CMOS memory becomes corrupted and the system does not boot, you can
restore the factory default values by following these steps:
1. Power off the system and disconnect the AC power.
2. Locate the CMOS reset jumper (J25) on the system board. See
A in Figure 6.

A
Figure 6. CMOS reset jumper J25

3. Remove the jumper, which is normally located on pins 1 and 2. (Pin 1 is located
near the edge of the board, while pin 3 is closest to the memory sockets.)
4. Place the jumper on pins 2 and 3 and wait for 5 seconds. This resets the
CMOS.
5. Return the jumper to pins 1 and 2.
6. Power ON the system.
7. When you restart the system after resetting the CMOS, the following error
message is displayed:
CMOS checksum error - defaults loaded

Chapter 2. Running diagnostics and troubleshooting 15

 To correct these errors, run the Setup Utility and select Load Optimized
Defaults. This restores the CMOS defaults. After the defaults are restored,
check the date and time, and set any other customer-specific settings that were
modified before the CMOS was reset.

Real-time clock and CMOS

The real-time clock is a low-power clock that provides a time-of-day clock and a
calendar. The clock settings are maintained by the battery when the power cord is
removed. Use the CMOS Setup Utility to set the clock and calendar. See “Standard
CMOS features” on page 14.

See “System-board battery – removing and replacing” on page 51 for the location of
the battery.

Configuring the COM (communication) ports

Each COM port of the 4846 product uses a unique I/O address and IRQ. Some
previous SurePOS 500 system units utilized PCI-based COM ports with a shared
IRQ. The system BIOS configures the COM ports for use by the operating system;
therefore, a separate driver is not required. (Serial port drivers from previous
SurePOS 500 systems are not supported or required.)

Use the CMOS Setup Utility to configure or modify the COM ports, the default I/O
address and the IRQ. If you make modifications, ensure that each port uses a
unique I/O and IRQ value. Using default values are highly recommended. The IBM
SurePOS 500 Series Operating System Installation Guide for Models 545 and 565
provides a list of port resources.

Using the IBM Diagnostics for POS Systems and Peripherals package
Diagnostics for the SurePOS 500 Models 545 and 565 are available on the IBM
Diagnostics for POS Systems and Peripherals package. This package installs to a
memory key (see “Supported memory keys” on page 17).

Note: The Diagnostics also supports IBM POS I/O on prior systems, if the BIOS
supports booting from a memory key.

Locate the instructions for using this package in the README file. This package
provides menu-driven tests and utilities that enable trained service technicians to
configure and test the I/O devices. Locate and download the service program code
from the IBM Retail Store Solutions Web site using the following steps:
1. Obtain a memory key. See “Supported memory keys” on page 17.
2. Access the IBM Retail Store Solutions Web site at: www.ibm.com/solutions/
retail/store/support.
3. Select Support on the left side of the panel, then select IBM SurePOS 500/600
Series.
4. Next, select SurePOS 500-xx5 Downloads.
5. Download the update program to a temporary location on the PC’s hard-disk
drive. Run the self-extracting program and respond to the messages that
display. This program writes the updates and provides instructions on inserting
the memory key.

16 Models 545 and 565 Hardware Service Guide

 6. If you have not previously changed the CMOS Utility settings, you can boot into
the diagnostics using the USB memory key: Insert the USB memory key and
power on the system. If you have previously changed the default settings, go to
Step 7.
7. If you have changed the default settings of the CMOS Setup Utility, follow these
steps:
a. Ensure that the Hard Disk is listed as the First Book Device under
Advanced BIOS Features, Hard Disk Boot Priority.
b. Power off the machine.
c. Plug the memory key into a USB port.
d. Power on the machine. The system BIOS recognizes the memory key and
adds it to the lists displayed by the CMOS Setup Utility.
e. Open the CMOS Setup Utility settings. Ensure that your settings are as
follows:
v Under Advanced BIOS Features, Hard Disk Boot Priority, ensure that
memory key is listed first.
v Under First Boot Device, ensure that Hard Disk is listed first.
f. Save these settings and exit. The system will boot automatically using the
memory key and the diagnostics program begins.

You have the option of using an attached keyboard, if available. The diagnostics
program will ask you to accept the user license agreement. Click the I Agree
button. You will be presented with a screen containing a selection menu for System
Components, Point Of Sale Devices, and Utilities (for VPD, and others). Sub-menus
are dynamically-tailored based upon your system—only tests available for your
machine type are displayed.

Supported memory keys

The following memory keys are supported by the SurePOS 500 Models 545 and
565:
IBM USB 2.0 (256 MB)
v FRU: 41D9746
v Part number: 22P9228
Go to www.ibm.com for details on this USB key.
PNY USB 2.0 (1 GB)
v Part number: P1886C53
Go to http://www2.pny.com/homepage.aspx for details on this USB key.

Updating the flash BIOS

Download the latest level of flash BIOS for the SurePOS 500 Models 545 and 565
by following the instructions for downloading the diagnostics.
1. Follow the steps described in “Using the IBM Diagnostics for POS Systems and
Peripherals package” on page 16
2. Switch the system ON again. The system boots from the memory key, the flash
BIOS update occurs.
3. Remove the memory key. The new BIOS update is on the system.

Note: The flash utility saves and restores your CMOS setting.

Chapter 2. Running diagnostics and troubleshooting 17

Power interruption during flash BIOS update procedure
If power is interrupted during the flash BIOS update procedure, the BIOS could
become corrupted. Should this event occur, the system boots automatically from a
backup copy of BIOS. To repair the corrupt version of BIOS and return to using the
normal BIOS, repeat the steps to update the flash BIOS.

Repairing the flash BIOS

Two separate copies of POST/BIOS are maintained in separate flash modules.
Should the primary copy become corrupt, the system automatically runs from the
backup copy when rebooted. A POST message indicates when the backup copy is
in use. When this happens, it is important to perform a Flash Update, in an attempt
to repair the primary copy and preserve the backup functionality. If the primary is
permanently damaged, the system runs normally, but without backup capability for
the BIOS, and the POST message appears at each boot up.

18 Models 545 and 565 Hardware Service Guide

Diagnosing problems and troubleshooting
A software error or a hardware failure can cause a problem with the system. The
following topics contain problem analysis instructions to help you determine the
cause of a problem and resolve it.

Table 10 describes the servicing task and the section that contains information
supporting the task.
Table 10. SurePOS 500 task information
Task Go to
Diagnosing a problem. “Preliminary checklist.”
Update the flash BIOS. “Updating the flash BIOS” on page 17.
Run the CMOS Setup Utility. “Using the CMOS Setup Utility” on page 13.
Using the service program. “Using the IBM Diagnostics for POS Systems
and Peripherals package” on page 16
Obtain the part number for the FRU. Appendix A, “Field replaceable parts,” on
page 95.
Remove or replace a field-replaceable unit Chapter 3, “Removing and replacing FRUs
(FRU). for the SurePOS 500 Models 545 and 565,”
on page 25.

Researching the Knowledgebase

You can determine if a product problem has been resolved. Just review the
symptoms and fixes in the knowledge base at the IBM Retail Stores Solutions Web
site.
1. Go to www.ibm.com/solutions/retail/store/.
2. Select Support.
3. Select IBM SurePOS 500/600 Series
4. Select Knowledgebase Tips and FAQs.

Preliminary checklist
When you power on the SurePOS 500, the system performs a power-on self-test
(POST). When the power LED stops blinking, POST is complete. If multiple beeps
occur, perform the following steps to diagnose the problem.
1. Ensure that all AC power is connected and observe the power light to make
sure that it is lit.
2. Ensure that all cables and I/O devices are connected correctly and securely.
3. Make sure that you correctly adjust the brightness setting, using the controls at
the bottom right side of the display.
4. Record any error messages or symptoms for troubleshooting.

If you do not observe a specific error indication, continue problem resolution at

“Troubleshooting symptoms and actions” on page 20.
Notes:
1. For internal options and peripheral devices, you can use the diagnostic service
program to help resolve problems.
2. For devices with separate test instructions, refer to those instructions when
testing.

Chapter 2. Running diagnostics and troubleshooting 19

 3. When using application software, you may receive error messages that pertain
to the software. Refer to the software manual for a description of those
messages.

Troubleshooting symptoms and actions

If the SurePOS 500 system fails with no error message or beep code, see Table 11
to find problem symptoms and take the related action.

Note: Corrupted CMOS may cause unpredictable problems. Before exchanging the
system board to resolve a problem, go to “Clearing the CMOS settings” on
page 15 and reset CMOS. Oftentimes, a corrupted CMOS is the source of
the trouble.
Table 11. Symptoms and actions
If the problem is... Here’s what to do.
No power light on the tower unit. 1. Ensure that the system unit is plugged into a working electrical outlet and
replug the power cable at the power supply.
2. Verify that the tablet display cable is plugged into the tablet.
3. Verify that the button/LED card in the tablet is plugged in properly.
4. Verify the power supply is properly installed.
5. Replace the power supply. See “Power supply – removing and replacing”
on page 45.
6. Replace the system board. See “System board – removing and replacing”
on page 49.
Operator display exhibits: 1. Adjust the brightness control at the bottom right side of the display.
Blank screen
2. Ensure that the tablet display cable is securely connected.
No cursor displayed
Screen is unreadable 3. Switch the unit off and the power on.
Other display problems. 4. Run the operator display test using the diagnostic service program.
5. Replace the LCD assembly. See “Front bezel and LCD assembly -
removing and replacing” on page 36.
6. Replace the system board. See “System board – removing and replacing”
on page 49.
For details on cash drawer removal and replacement procedures, see the IBM Point of Sale Options and I/O Devices
Service Guide, GC30-9737. Throughout this text, this book is referred to as the I/O book.
Cash drawer does not open when 1. Replace the keylock insert if the lock does not turn with the key. See the
cash drawer key is turned to the open I/O book.
position.
2. Gently pull the drawer open while holding the key turned to the open
position to determine if the slide assembly is binding. Look for items that
may cause binds, such as pens or paper clips. Replace the slide
assembly if necessary.
3. Replace the cam, pawl, and spring kit.
4. Check for a bent actuator rod. Replace the actuator rod if necessary.
Cash drawer does not stay closed. 1. Make sure that the keylock is not bound in the open position. Replace the
keylock if necessary.
2. Replace the cam, pawl, and spring kit.
3. Replace the latch and the sensor assembly card.
4. Replace the cash drawer.
5. Replace the system board. See “System board – removing and replacing”
on page 49.

20 Models 545 and 565 Hardware Service Guide

Table 11. Symptoms and actions (continued)
Cash drawer does not open or close 1. Look for items that could cause binding. Pens or paper clips trapped
smoothly, or appears to be binding. between the drawer and cover or the drawer and base could cause
binding.
2. Compact drawer only: Remove the drawer and the rollers at the rear of
the drawer and at the front of the base. Replace the rollers if necessary.
3. Determine if the slide assembly in the base is binding. Replace the slide
assembly if necessary.
Cash drawer not opening 1. Run the CMOS Setup Utility to make sure that IBM cash drawer setting is
enabled.
2. Ensure that the cash drawer cable is securely connected.
3. Replace the cash drawer cable.
4. Replace the cash drawer latch assembly.
5. Replace the system board.
Cash drawer does not open when 1. Replace the latch and the sensor assembly card.
performing store transactions or
2. Replace the cash drawer cable.
running cash drawer tests, but it opens
when the cash drawer key is turned to 3. Replace the system board. See “System board – removing and replacing”
the open position. on page 49.
The status displayed by the cash 1. Replace cable.
drawer tests does not match the
2. Replace the latch and the sensor assembly card.
physical status of the cash drawer
being tested. For example, the test 3. Replace the system board. See “System board – removing and replacing”
indicates that cash drawer A is closed on page 49.
when cash drawer A is actually open.
Magnetic stripe reader (MSR) not 1. Check the three-track MSR dip switch settings for either RS232 or
reading. keyboard interface.
2. Run the CMOS Setup Utility and check the setting in the MSR serial port.
3. Ensure that the MSR cable is securely connected.
4. Run the MSR test using the diagnostic service program.
5. Reset to factory defaults by pressing the Reset button with a paper clip.
The MSR must be removed temporarily from the side of the tablet to
access the reset button. Leave the MSR cable connected, and the unit
powered ON when pressing the Reset button.
6. Replace the MSR. See “Magnetic stripe reader (MSR) – removing and
replacing” on page 58.
Operator display backlight: dark, dim, 1. Adjust the brightness using the button located on the front of the display.
or partially lit.
2. Ensure tablet display cable is securely attached under display tablet and
at system board.
3. Replace the LCD assembly, see “Front bezel and LCD assembly -
removing and replacing” on page 36.
Touch screen not working. 1. Ensure tablet display cable is securely attached under display tablet and
at system board.
2. Run the touch screen test using the diagnostic service program.
3. Reinstall the touch driver.
4. Replace the front touch bezel assembly. See “Front bezel and LCD
assembly - removing and replacing” on page 36.
5. Replace the system board. See “System board – removing and replacing”
on page 49.

Chapter 2. Running diagnostics and troubleshooting 21

Table 11. Symptoms and actions (continued)
PS/2 keyboard does not work or only 1. Ensure that the keyboard cable is securely connected.
some keys work.
2. Move your fingers across the keys, making sure that no keys are stuck.
3. Ensure that you are on a window that allows typing. Some windows do
not allow you to type on them.
4. Run the keyboard test from the diagnostics program.
5. Replace the keyboard.
Diskette drive does not work. 1. Check the diskette drive cable connections.
2. Run the CMOS Setup Utility to make sure the diskette drive controller is
enabled.
3. Ensure that the correct boot device is selected in the CMOS Setup Utility,
which is USB–FDD.
4. Verify the hardware by attempting to load a bootable diskette.
5. If the drive will not boot with a bootable diskette, replace the drive and
cable.
6. Replace the system board.
Audio is not working. 1. Check the volume control.
2. Check the speaker cable connections.
3. Run CMOS Setup Utility to make sure the audio is enabled.
4. Replace the speaker.
5. Replace the system board.
Fan continues running after system This is normal operation with the power supplies.
has been powered Off.

Notes:
1. Some devices that attach to the system have test instructions. Refer to those
instructions when testing those devices.
2. Record any error messages or symptoms for future reference.
3. When using application programs, you may receive error messages that pertain
to the application software. See the application program manual for a
description of those messages.

22 Models 545 and 565 Hardware Service Guide

CMOS recovery
If the CMOS memory becomes corrupted and the system does not boot, restore the
factory default values by following the procedure described in “Clearing the CMOS
settings” on page 15.

Always reset CMOS (as described at “Restoring the default CMOS settings” on
page 15) before replacing a system board to resolve a problem. This practice
allows you to determine if a corrupted CMOS is the source of the trouble. A
corrupted CMOS can cause unpredictable problems.

Chapter 2. Running diagnostics and troubleshooting 23

24 Models 545 and 565 Hardware Service Guide
Chapter 3. Removing and replacing FRUs for the SurePOS
500 Models 545 and 565
Pictorial overview . . . . . . . . . . . . . . . . . . . . . . . . 26
Handling static-sensitive devices . . . . . . . . . . . . . . . . . . 28
Modular servicing and minimum tools . . . . . . . . . . . . . . . 28
Removing the covers . . . . . . . . . . . . . . . . . . . . . . 29
Front (or HDD) cover removal . . . . . . . . . . . . . . . . . . 29
Rear cover removal . . . . . . . . . . . . . . . . . . . . . . 30
Opening the I/O tailgate cover . . . . . . . . . . . . . . . . . . 31
Top cover removal . . . . . . . . . . . . . . . . . . . . . . 32
Hinge cover removal . . . . . . . . . . . . . . . . . . . . . . 33
Display tablet - removing and replacing . . . . . . . . . . . . . . . . 34
Display tablet cable – removing and replacing . . . . . . . . . . . . 35
Front bezel and LCD assembly - removing and replacing . . . . . . . . . 36
Operator card - removing and replacing . . . . . . . . . . . . . . . 38
Tablet hinge assembly – removing and replacing . . . . . . . . . . . . 39
Hard disk drive and bracket – removing and replacing . . . . . . . . . . 40
Hard disk drive fan and bracket – removing and replacing . . . . . . . . . 42
Hard disk drive cables – removing and replacing . . . . . . . . . . . . 43
Cable tie bar – removing and replacing . . . . . . . . . . . . . . . . 44
Power supply – removing and replacing . . . . . . . . . . . . . . . . 45
Power supply latch arm – removing and replacing . . . . . . . . . . . . 46
Rear connector panel (tailgate) – removing and replacing . . . . . . . . . 47
System board – removing and replacing . . . . . . . . . . . . . . . 49
System-board jumper location and settings . . . . . . . . . . . . . 51
System-board battery – removing and replacing . . . . . . . . . . . . 51
Processor fan/heatsink assembly - removing and replacing . . . . . . . 53
Processor module – removing and replacing . . . . . . . . . . . . . 54
Memory modules – removing and replacing . . . . . . . . . . . . . . 55
Memory modules and industry standards . . . . . . . . . . . . . . 56
Base plate – removing and replacing . . . . . . . . . . . . . . . . . 57
Optional features . . . . . . . . . . . . . . . . . . . . . . . . 58
Magnetic stripe reader (MSR) – removing and replacing . . . . . . . . . 58
MSR hole plug – removing and replacing . . . . . . . . . . . . . . 58
PC card blank – removing . . . . . . . . . . . . . . . . . . . . 59
PC card – removing and replacing . . . . . . . . . . . . . . . . . 59
Video adapter card– removing and replacing . . . . . . . . . . . . . 61
Speaker – removing and replacing. . . . . . . . . . . . . . . . . 62
Integrated customer display – removing and replacing . . . . . . . . . 64

This section contains the FRU removal and replacement procedures for all
SurePOS 500 Models 545 and 565 models (4846). Some procedures are for
features that are not available on all models.
Notes:
1. Before you perform any removal and replacement procedures, see the sections
entitled “Safety Information” on page xi and “Handling static-sensitive devices”
on page 28.
2. The machine serial number for the 4846 is located on the lower right, front
frame. See Figure 4 on page 11.
3. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.

© Copyright IBM Corp. 2006 25

Removing and replacing FRUs

Pictorial overview
The SurePOS 500 Series Models 545 and 565 is designed for modular servicing
and installation. Figure 7 on page 27 shows the progression and ease of some
common removals.
Table 12. Pictorial overview of common removal tasks
See Figure 7 on
page 27: Task: Section with complete details:
A Opening the rear cover “Rear cover removal” on page 30
B Removing the power “Power supply – removing and replacing” on
supply page 45
C Opening the tailgate “Rear connector panel (tailgate) – removing and
replacing” on page 47
D Removing the tailgate
E Removing the top “Top cover removal” on page 32
cover
F Removing the system “System board – removing and replacing” on
board page 49
G Opening the front cover “Front (or HDD) cover removal” on page 29
H Removing the “Hard disk drive and bracket – removing and
hard-disk drive replacing” on page 40
I Opening the “Front bezel and LCD assembly - removing and
touch-cable cover replacing” on page 36
J Removing the front
bezel

26 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

A B C

D E F

G H I

Note: These pictures represent only some of the common component removals.
Figure 7. Pictorial overview

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 27
Removing and replacing FRUs

Handling static-sensitive devices

Attention: Static electricity can damage electronic devices and your system. To
avoid damage, keep static-sensitive devices in their static protective bags until you
are ready to install them.

To reduce the possibility of electrostatic discharge, observe the following

precautions:
v Limit your movement. Movement can cause static electricity to build up around
you.
v Handle the device carefully, holding it by its edges or its frame.
v Do not touch solder joints, pins, or exposed printed circuitry.
v Do not leave the device where others can handle and possibly damage the
device.
v While the device is contained in its anti-static bag, touch it and your finger to an
unpainted metal part of the system unit for at least 2 seconds. (This action
removes static electricity from the package and from your body.)
v Remove the device from its package and install it directly into your system,
without putting it down. If it is necessary to put the device down, place it onto its
static-protective bag. (If your device is an adapter, place it component side up.)
Do not place the device onto the cover of the system or onto a metal table.
v Take additional care when handling devices during cold weather because heating
reduces indoor humidity and increases static electricity.

Modular servicing and minimum tools

The SurePOS 500 Models 545 and 565 were designed for modular servicing and
requires the minimum use of tools. However, some field replacement parts may
require a tool. Table 13 lists the part number for tools that you may need for
servicing.
Table 13. Service personnel tools
Description Part Number Units
Wrap plug, Ethernet 00G2380 1
Wrap plug, RS-232 72X8546 1
Adapter cable, RJ-45 to 9-pin 40N5341 1
conversion

28 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Removing the covers

This section describes how to remove the front, top, rear, tower, and side covers.

Front (or HDD) cover removal

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Tilt the top of the display tablet back.
3. Press inward on the buttons on each side of the front cover
A(see Figure 8),
and pull the front cover/HDD cover slightly forward.

Figure 8. Unlatching the front cover

4. Lift the cover forward and away from the unit.

5. To replace, reverse these procedures.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 29
Removing and replacing FRUs

Rear cover removal

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Facing the rear of the system, press down on the latch, and rotate the top away
as shown in Figure 9, and lift the rear cover away from the unit.

Figure 9. Removing the rear cover

3. To replace, reverse these procedures.

30 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Opening the I/O tailgate cover

Open the I/O tailgate cover as follows:

Figure 10. Opening the I/O tailgate cover

v Remove the rear cover as described in “Rear cover removal” on page 30.
v Unlatch the I/O tailgate cover by sliding the latches (
A in Figure 10) toward the
center.
v Open the I/O tailgate cover by rotating it downward.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 31
Removing and replacing FRUs

Top cover removal

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover, following the procedure in “Rear cover removal” on
page 30.
3. Open the I/O tailgate cover (see “Opening the I/O tailgate cover” on page 31).

Figure 11. Locating the top cover release latch

4. Facing the rear of the system, use a screwdriver to lift the latch (
Ain
Figure 11), while sliding the top cover toward you (toward the rear of the unit)
5. Repeat for the latch on the other side.
6. To replace, slide the top cover on from the rear.

32 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Hinge cover removal

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the display tablet. See “Display tablet - removing and replacing” on
page 34.
3. Remove the HDD or front cover. See “Front (or HDD) cover removal” on page
29
4. Remove the top cover as described in “Top cover removal” on page 32.
5. Remove the center cover (
C) by lifting it off.

Figure 12. Removing the hinge cover

6. Lift off to remove the hinge cover (
D).

Note: You will need to pull the sides of the hinge cover away from the hinge so
that features (
E) will clear holes (
F in Figure 12).

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 33
Removing and replacing FRUs

Display tablet - removing and replacing

Follow these procedures to remove the display tablet.

Figure 13. Removing the display tablet

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Tilt the tablet back and loosen the two thumbscrews
A in Figure 13 under the
tablet.
3. If present, unplug the MSR cable.
4. Disconnect the cable from the rear of the tablet by pressing on either side of the
connector.
5. Lift the tablet off the unit.
6. To replace, reverse these procedures.

34 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Display tablet cable – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the tablet as described in “Display tablet - removing and replacing” on
page 34.
3. Disconnect the display cable from the rear of the tablet by pressing on either
side of the connector.
4. Remove the front cover as described “Front (or HDD) cover removal” on page
29.
5. Remove the speaker, if present. See “Speaker – removing and replacing” on
page 62.
6. Remove the rear cover as described in “Rear cover removal” on page 30.
7. Remove the power supply as described in “Power supply – removing and
replacing” on page 45.

Figure 14. Removing the display tablet cable from the system board

8. Remove the clamps on front of the frame and hinge.

9. Disconnect the display tablet cable from the system board by loosening the
two thumbscrews (see Figure 14).
10. Remove the base plate. See “Base plate – removing and replacing” on page
57.
11. Pull the cable free from the plastic guide in the frame.
12. To replace, reverse these procedures.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 35
Removing and replacing FRUs

Front bezel and LCD assembly - removing and replacing

Note: The front bezel and the LCD assembly are available as FRUs.
1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. If installed, remove the MSR and antenna cover assembly. See “Magnetic stripe
reader (MSR) – removing and replacing” on page 58.

Figure 15. Disconnecting the touch cable and removing the front bezel

3. Remove the touch cable door by lifting on the latch and lifting outward. The
cable door will dangle from the connecting tie.
4. Disconnect the touch cable by lifting the connector lever to the open position
(
O in Figure 15) and lifting out the cable.

Note: The OPEN position is away from the touch card and perpendicular to the
unit, while the LOCKED position (
L) is closer to the touch card and
parallel with the unit.

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 Removing and replacing FRUs

Figure 16. View of L-shaped keyways

5. Press the buttons on either side of the tablet (
V in Figure 15 on page 36) to
unlock the bezel, and lift upward until the bezel stops. Then pull the bezel away
from the tablet.
6. Continue to lift the LCD assembly from the front bezel assembly and remove.
7. To replace the front bezel or LCD assembly from the front bezel assembly,
reverse these procedures and reconnect the touch cable:
a. Ensure that the connector lever is in the open position. See Figure 15 on
page 36.
b. Insert the cable behind the connector lever.
c. Push the connector lever to the locked position (
L in Figure 15 on page
36).

Note: When replacing the front bezel, be sure to align the tabs in the front
bezel into the keyways. See
Z in Figure 16.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 37
Removing and replacing FRUs

Operator card - removing and replacing

This section describes how to remove the operator card.
1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Follow the steps described in “Front bezel and LCD assembly - removing and
replacing” on page 36 to lift off the front bezel.

D
Figure 17. Removing the operator card

3. Disconnect the cable from the operator card.

4. See Figure 17. Remove the two screws (
D) and lift out the card.
5. To replace, reverse these procedures.

38 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Tablet hinge assembly – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the tablet as described in “Display tablet - removing and replacing” on
page 34
3. Remove the front cover as described in “Front (or HDD) cover removal” on page
29
4. Remove the top cover. See “Top cover removal” on page 32

Figure 18. Removing the tablet hinge assembly

5. Lift to remove the tower center cover and the hinge cover (see “Hinge cover
removal” on page 33).
6. Remove the four screws shown in Figure 18 and lift off the hinge assembly.
7. To replace, reverse these procedures.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 39
Removing and replacing FRUs

Hard disk drive and bracket – removing and replacing

Attention: The hard disk drive (HDD) is a static-sensitive device. See “Handling
static-sensitive devices” on page 28. User care not to drop or jar the HDD during
assembly. Do not use an impact power driver.

Note: The HDD and bracket are available together as one FRU, and are also
available separately.

Figure 19. HDD installation. For clarity, this figure shows additional components removed;
however, you do not remove these to remove the HDD.

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. As shown in Figure 19, tilt back the tablet.
3. Remove the front cover as described at “Front (or HDD) cover removal” on
page 29.
4. Disconnect the two cables from the HDD.

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 Removing and replacing FRUs

Figure 20. Removing the hard disk drive and bracket. For clarity, this figure shows additional
components removed; however, you do not remove these to remove the HDD.

5. See Figure 20. Loosen the captive thumbscrew (
A) and remove the HDD
assembly by lifting it off of the hooks on the frame (
B).
6. If the HDD is a separate FRU, place the HDD on a flat surface and remove the
four screws and bracket.
7. Place the old HDD in protective packaging.
8. Attach the bracket to the new HDD with the four screws.
9. Reinstall the HDD and bracket assembly:
a. Reconnect the power and data cables to the HDD.
b. Reinsert the HDD and bracket into the frame hooks and replace the
thumbscrew
10. Replace the HDD cover.
11. Power on the system and use the CMOS Setup Utility to verify that the system
recognizes the new HDD.

Note: If the system fails to recognize the new HDD, verify that all connectors
are properly seated and that the address jumper is correctly installed. If
the HDD requires a jumper to be recognized as Drive 0, the correct
position is indicated on a label on the HDD.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 41
Removing and replacing FRUs

Hard disk drive fan and bracket – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover as described in “Rear cover removal” on page 30
3. Remove the top cover (
A in Figure 21) as described in “Top cover removal” on
page 32.

B
C

Figure 21. Removing the HDD fan and bracket

4. Remove the tower center cover (
Bin Figure 21) by lifting upward.
5. See Figure 21. Unsnap and remove the HDD fan (
C) and bracket to remove.
6. Disconnect the cable from the fan.
7. To replace, reverse these procedures.

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 Removing and replacing FRUs

Hard disk drive cables – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Tilt back the tablet.
3. Remove the front cover as described at “Front (or HDD) cover removal” on
page 29.
4. If present, remove the speaker. See “Speaker – removing and replacing” on
page 62.
5. Remove the HDD power connector and data cable connector from the HDD.
6. Cut any cable ties on the cables.
7. Disconnect the power cable and the data cable from the system board.
8. Remove the base plate. See “Base plate – removing and replacing” on page
57.
9. Pull the power cable free from the plastic guide in the frame.
10. To replace, reverse these procedures.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 43
Removing and replacing FRUs

Cable tie bar – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Follow the instructions described in “Rear cover removal” on page 30.

Figure 22. Removing the cable tie bar

3. Loosen the captive thumbscrew
B, as shown in Figure 22.

4. Remove the latch arm from the hinge by rotating and sliding it from the slots.
5. To replace, reverse these procedures.

44 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Power supply – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the back cover as described at “Rear cover removal” on page 30.
3. Unplug the AC power cord on the back of the power supply.
4. Unlatch the power supply latch arm by loosening the captive thumbscrew and
swinging the arm upward.
5. Lift upward until it stops.
6. Pull the power supply out.

Figure 23. Removing the power supply

7. To replace, make sure the latch arm is all the way up. Slide the power supply
into the bottom of the system unit until it stops. Ensure that the power supply
latch arm hooks go inside the metal frame.
8. Rotate the latch arm downward and replace the thumbscrew.

Note: You may need to push in at the left bottom of the power supply to get the
thumbscrew to align with the screw hole.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 45
Removing and replacing FRUs

Power supply latch arm – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Follow the instructions described in “Rear cover removal” on page 30.
3. Follow the instructions described in “Power supply – removing and replacing” on
page 45

Figure 24. Removing the power supply latch arm

4. Remove screws (
H) and then lift off the power supply.
5. To replace, reverse these procedures.

46 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Rear connector panel (tailgate) – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover as described at “Rear cover removal” on page 30.
3. Disconnect all I/O cables from the tailgate:
v Speaker
v Video
v Serial ATA
v Power
4. Remove the power supply. See “Power supply – removing and replacing” on
page 45.

Figure 25. Opening the I/O tailgate cover

5. Unlatch the I/O tailgate cover by sliding the latches (
A in Figure 25) toward the
center.
6. Open the I/O tailgate cover by rotating it downward.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 47
Removing and replacing FRUs

Figure 26. Removing the tailgate

7. As shown in Figure 26, pull the I/O tailgate and attached I/O tailgate cover from
the system board.
8. To replace, reverse these procedures, being sure to align the metal tabs on the
side of the tailgate with the plastic guides on the frame.

48 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

System board – removing and replacing

Attention: Establish personal grounding before touching this unit. See
“Electrostatic Discharge (ESD)” on page 130.

Note: The system board assembly comes with a tray and top cover.

Figure 27. Removing the system board

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Follow the steps described in “Rear cover removal” on page 30.
3. Remove the power supply as described in “Power supply – removing and
replacing” on page 45
4. Disconnect the cables and remove the I/O tailgate cover as described in “Rear
connector panel (tailgate) – removing and replacing” on page 47
5. Grasp the entire assembly and slide it out toward the top as shown in Figure 27.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 49
Removing and replacing FRUs

Transfer modules to the new system board

Place the assembly on a table and remove the following parts:
v Memory modules – See “Memory modules – removing and replacing” on
page 55.
v Heatsink and fan - See “Processor fan/heatsink assembly - removing and
replacing” on page 53.
v Processor – See “Processor module – removing and replacing” on page
54.
v Video adapter, if installed. See “Video adapter card– removing and
replacing” on page 61.
v Optional integrated VFD
Install these parts on the new system board. The new system board comes
with all required jumpers and with a new battery.
Update system software
1. Ensure system BIOS is equal to or greater than that from the old
system board. See “Updating the flash BIOS” on page 17.
2. Reprogram the Vital Product Data (VPD).
a. Boot using the memory key.
b. Choose POS System Test.
c. Choose Utilities.
d. Choose Vital Product Data Utility.
e. Choose Update VPD.
f. Choose the model and press Enter.
g. Choose Update VPD again.
h. Enter the machine serial number and press Enter.
i. Exit.

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 Removing and replacing FRUs

System-board jumper location and settings

Figure 28 shows the system-board jumper locations. See the following topics for
jumper descriptions and information about jumper settings.

A
Figure 28. System board jumper location

Table 14 describes the system board jumper setting. All jumper pins have the pin
number printed on the system board for easy identification.
Table 14. System board jumper settings
Jumper Default pin Description
location:
J25 pins 1 and 2 CMOS Memory clear: To clear the CMOS, momentarily
place the jumper on pins 2 and 3

Note: Pin 1 is indicated by a notched corner in the silkscreen.

System-board battery – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover as described at “Rear cover removal” on page 30.
3. Remove the power supply. See “Power supply – removing and replacing” on
page 45
4. Remove the I/O tailgate as described in “Rear connector panel (tailgate) –
removing and replacing” on page 47

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 51
Removing and replacing FRUs

Figure 29. System-board battery

5. Remove the old battery from the slot
L as shown in Figure 29.
6. Facing the rear of the machine, insert the new battery with the positive side to
the left

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 Removing and replacing FRUs

Processor fan/heatsink assembly - removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover as described at “Rear cover removal” on page 30.
3. Remove the power supply. See “Power supply – removing and replacing” on
page 45
4. Remove the I/O tailgate cover as described in “Rear connector panel (tailgate) –
removing and replacing” on page 47
5. Unplug the processor fan cable.

Figure 30. Removing the processor fan/ heatsink assembly. The placement of the unit in the
top view is for illustrative purposes only.

6. Press the latch (
Ain Figure 30) on the processor fan bracket and rotate fan
bracket away from the duct.
7. Remove the processor fan/heatsink by loosening the four screws.
8. See “Processor module – removing and replacing” on page 54 to remove the
processor.
9. Reverse these procedures to replace.

Note: If you are reusing the existing heatsink, make sure that the thermal material
is not torn or damaged. Replace, if needed. The thermal material comes
installed on a new heatsink or with a new processor.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 53
Removing and replacing FRUs

Processor module – removing and replacing

Note: The processor and fan sink come as one FRU. Do not use the old fan sink
when replacing the processor.

Attention: Establish personal grounding before touching this unit. See “Electrostatic
Discharge (ESD)” on page 130.

The LGA 775 CPU socket contains very finely pitched pins. You must take care
when servicing the CPU as any damage to the socket results in a non-functional
system board. Be sure to use the section cup tool provided with the FRU
1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover as described at “Rear cover removal” on page 30.
3. Remove the power supply as described in “Power supply – removing and
replacing” on page 45.
4. Remove the tailgate as described in “Rear connector panel (tailgate) – removing
and replacing” on page 47.

Attention: The SurePOS Models 545 and 565 contain a LGA 775 CPU socket.
This socket contains very finely pitched pins. You must take care when servicing the
CPU as any damage to the socket results in a non-functional system board. Be
sure to use the section cup tool provided with the FRU processor.
5. Remove the processor fan/heatsink assembly as described in “Processor
fan/heatsink assembly - removing and replacing” on page 53.

Note: Examine the thermal interface on the new heatsink. If the thermal
interface is damaged, replace the heatsink.
6. Release the latch and carefully remove the processor from the system board.
7. To replace, reverse these procedures.

54 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Memory modules – removing and replacing

Attention: Establish personal grounding before touching this unit. For more
information, see “Electrostatic Discharge (ESD)” on page 130.

All system boards have 2 memory sockets. See Figure 31. The factory-installed
base memory occupies one of the sockets. If you order is greater than the base
memory, you may or may not have an empty socket.

Figure 31. Memory socket location

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the back cover. See “Rear cover removal” on page 30.
3. As shown in Figure 25 on page 47, lower the I/O tailgate cover.
4. Locate the memory modules. See
A in Figure 31.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 55
Removing and replacing FRUs

Retainer

Figure 32. Memory module removal

5. Press the latches away from the module as shown in Figure 32.
6. Touching only the top corners of the module, pull it gently until it is free from
the socket.
7. Before inserting a replacement module, note the alignment notch along the
bottom of the module and where the module plugs into the slot. cass1eco
8. Carefully align the module in the slot and then press it into the slot until it is
secured by the clip.

Note: Ensure the memory module is fully seated in the socket and the retainer
tabs are fully upright and engaged in the memory module side notches.
9. Replace the I/O tailgate cover.
10. Replace the rear cover.

Memory modules and industry standards

You should only use memory provided by IBM Retail for use in Models 545 and
565. Although advertised as industry standard, all memory does not work with every
product, IBM performs extensive life and reliability testing to insure that memory
offered by IBM will operate correctly over all voltage and temperature ranges.

56 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Base plate – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover as described in “Rear cover removal” on page 30.
3. Open the cable tie bar and disconnect all of the cables.
4. Remove the two screws
S attaching the base plate to the frame.
5. Slide the tower toward the rear and lift it off the base.

Figure 33. Removing the base plate

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 57
Removing and replacing FRUs

Optional features
This section describes how to remove and replace the optional features.

Magnetic stripe reader (MSR) – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Unplug the MSR cable
A, as shown in Figure 34 and remove the cable from
the cable groove
B.
3. Remove the thumbscrew
C that secures the MSR.
4. Slide the MSR
D up and off.

A
C

Figure 34. Removing the MSR

To replace the MSR, reverse this procedure.

Note: If you are replacing a dual-sided, single-track MSR, you must set the switch
under the MSR cover next to the slot to either the RS-232 or keyboard
position, depending on the configuration of the MSR removed.

After installation, run the diagnostics to ensure that the MSR operates correctly. See
“Using the IBM Diagnostics for POS Systems and Peripherals package” on page
16.

MSR hole plug – removing and replacing

1. Use a screwdriver to pry off the MSR hole plug.
2. To replace, align plug with hole and press.

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 Removing and replacing FRUs

PC card blank – removing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the HDD cover. See “Front (or HDD) cover removal” on page 29.
3. Remove the door in the direction shown in Figure 35.

Figure 35. Removing the PC card adapter slot blank

PC card – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the front cover. See “Front (or HDD) cover removal” on page 29.
3. Remove the PC card cover as shown in Figure 35.
4. If a wireless LAN antenna cover is present, remove the two screws, as shown in
Figure 36 on page 60.
5. Press the PC card adapter eject button. Do not pull the interface cable to
remove the adapter card and connector. Gently pull on the adapter card.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 59
Removing and replacing FRUs

Figure 36. Removing a PC card adapter

6. To replace, reverse these procedures.

For information about defining the PC card to the system, see “Using the CMOS
Setup Utility” on page 13.

Note: Before removing a PC card with the system unit running Windows, IBM
recommends that you stop the PC card in Windows before you physically
remove it.

After installation, run the diagnostics to ensure that the PC card operates correctly.
See “Using the IBM Diagnostics for POS Systems and Peripherals package” on
page 16.

60 Models 545 and 565 Hardware Service Guide

 Removing and replacing FRUs

Video adapter card– removing and replacing

Attention: The dual-video adapter is a static-sensitive device. See “Handling
static-sensitive devices” on page 28.
1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the back cover as described at “Rear cover removal” on page 30.
3. Remove the power supply. See “Power supply – removing and replacing” on
page 45
4. Remove the three screws shown in Figure 37 and remove the video adapter
card.

Figure 37. Video adapter card removal

5. To replace, reverse these procedures.

After installation, run the diagnostics to ensure that the video adapter card operates
correctly. See “Using the IBM Diagnostics for POS Systems and Peripherals
package” on page 16.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 61
Removing and replacing FRUs

Speaker – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the front cover as described in “Front (or HDD) cover removal” on page
29

J
Figure 38. Removing the speaker thumbscrew

3. Loosen the speaker cover thumbscrew as shown in
J in Figure 38.

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 Removing and replacing FRUs

Figure 39. Removing the speaker and speaker EMC shield

4. Slide the speaker shield to the left and lift it off of the hooks (
Hin Figure 39) to
remove.
5. Disconnect the speaker cable from the speaker extension cable.
6. To replace, reverse these procedures.

Note: The speaker hooks must fit into the hooks on the frame, or the HDD cover
will not close properly.

Chapter 3. Removing and replacing FRUs for the SurePOS 500 Models 545 and 565 63
Removing and replacing FRUs

Integrated customer display – removing and replacing

1. Switch OFF the power to the SurePOS 500. Unplug the power cord from the
external power source.
2. Remove the rear cover. See “Rear cover removal” on page 30.
3. Open the I/O tailgate cover by opening the latches and lowering the cover.

Note: You do not need to remove the tailgate cover.

4. Disconnect the integrated display cable from the rear of the system board.

Figure 40. Removing the integrated display

5. Remove the existing integrated display or top cover. See “Top cover removal”
on page 32.
6. Snap the new integrated display in place, after routing the cable through the
hole (
A in Figure 40 in the top of the unit.
7. Connect the cable to the rear upper-right corner (
B) of the system board.
8. Close the I/O tailgate cover and replace the rear cover.
9. To replace, reverse these procedures.

After installation, run the diagnostics to ensure that the integrated display operates
correctly. See “Using the IBM Diagnostics for POS Systems and Peripherals
package” on page 16.

64 Models 545 and 565 Hardware Service Guide

Chapter 4. Mounting the SurePOS 500 Models 545 and 565
Mounting the base plate on a countertop . . . . . . . . . . . . . . . 67
Non-keyboard-integration tray mounting . . . . . . . . . . . . . . . . 70
Countertop with non-keyboard-integration tray mounting . . . . . . . . . 70
Installing filler panels without a printer . . . . . . . . . . . . . . 75
Cash drawer . . . . . . . . . . . . . . . . . . . . . . . . . 75
Keyboard-integration tray . . . . . . . . . . . . . . . . . . . . . 80
Countertop and full-size cash drawer . . . . . . . . . . . . . . . . 80
Mounting the integration tray to a countertop . . . . . . . . . . . . 80
Installing additional peripheral devices . . . . . . . . . . . . . . . . 89
Mounting a distributed customer display and APA display to a cash drawer 89
Installing IBM 4610 SureMark Models TF6 or TF7 printers . . . . . . . . 91

Table 15 describes the various mounting configurations of the SurePOS 500.

Note
Figures in this section are representative of the SurePOS 500 family and may
have slight differences with the Models 545 and 565. All mounting procedures
are accurate.

Table 15. Mounting configurations

To mount using the base to the
countertop, see “Mounting the
base plate on a countertop” on
page 67.

© Copyright IBM Corp. 2006 65

Mounting the Models 545 and 565

Table 15. Mounting configurations (continued)

To mount to a countertop using
the non-keyboard-integration tray,
see “Countertop with
non-keyboard-integration tray
mounting” on page 70.

To mount on a cash drawer using

the non-keyboard-integration tray,
see “Cash drawer” on page 75.

66 Models 545 and 565 Hardware Service Guide

 Mounting the Models 545 and 565

Table 15. Mounting configurations (continued)

To mount on a countertop or cash
drawer using the
keyboard-integration tray, see
“Countertop and full-size cash
drawer” on page 80

Before mounting your system, first install any internal and external devices on the
unit.

Mounting the base plate on a countertop

You can mount the SurePOS 500 Models 545 and 565 free-standing base plate to a
countertop with two or four mounting screws. If you are routing the cables under the
counter, you can use the base plate as a pattern to cut out your counter or use the
specific mounting hole and cutout dimensions as shown in Figure 41 on page 68.

Chapter 4. Mounting the SurePOS 500 Models 545 and 565 67

Mounting the Models 545 and 565

(2x
)0 166 18
7.2

(2x) 3

(2x) 211.7
25
18

(2x) 8.8mm
13.85
.2
07

133 35
x)
(2

173.7 19.15

Figure 41. Base plate countertop dimensions

Route all cables (including the AC power cord) through the cable-access hole in the
base plate. If you are routing the cables on top of the counter, route all cables out
the rear of the system. Lay the cables flat along the countertop.

68 Models 545 and 565 Hardware Service Guide

 Mounting the Models 545 and 565

To mount the system directly on a countertop:

Note: Before you begin, acquire two mounting screws. These are not supplied.
1. Remove the rear cover.
2. Remove the cable-tie bar by loosening the thumbscrew.
3. Use the SurePOS 500 base plate as a pattern for drilling two mounting-screw
holes at location
S in Figure 42. If you plan to route the cables underneath
the counter, use the base plate as a pattern to drill the cable opening and for
drilling the holes for the mounting screws.
4. Attach the system to the countertop with two mounting screws.

Figure 42. Attaching the base foot to the countertop

5. Connect the power cable to the power supply.

6. Connect the peripheral device cables to the appropriate ports on the rear
connector panel. Make the connections on the bottom row of the connector
panel first and work upward. Ensure that the cables are routed to the right of
the power cord.

Note: For a diagram of the port layout, see “Connectors, power, and
brightness controls” on page 5.
7. Rotate the cable-tie bar back into place and tighten the thumbscrew.
8. Use tie-wraps to secure cables to the cable-tie bar, if desired.
9. Replace the rear cover.
10. Plug the AC power cord into an AC outlet.
11. After your installation is complete, switch ON the power to the SurePOS 500
and verify that the system is operating correctly by checking the indicator lights
(LEDs) on the front of the touch screen.
12. Install your software. Refer to IBM SurePOS Model 545 and 565 Operating
System Installation Guide.

Chapter 4. Mounting the SurePOS 500 Models 545 and 565 69

Mounting the Models 545 and 565

Non-keyboard-integration tray mounting

Some integration trays for countertop are designed to accommodate a keyboard
and cash drawers, and some are not. The procedures in this section are for
non-keyboard-integration tray mounting for the countertop and cash drawer. For
keyboard-integration tray mounting, go to “Countertop and full-size cash drawer” on
page 80.

Countertop with non-keyboard-integration tray mounting

Figure 43. Countertop with non-keyboard-integration tray mounting

The countertop integration tray can be used as a free-standing unit or secured to a

countertop using mounting screws. Use the countertop integration tray drawing that
comes with it as a pattern for drilling the four mounting holes and for the cable
opening, if you plan to route the cables through the countertop. Four screws (not
provided) are required to mount the integration tray to a countertop. For specific
mounting hole and cutout dimensions, see Figure 44 on page 71.

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 Mounting the Models 545 and 565

441.52 mm (17.38 in.)

90 mm 149 mm 128 mm
(3.54 in.) (5.87 in.) (5.04 in.)

66.22 mm 66.22 mm
(2.6 in.) (2.6 in.)
7 mm
(0.28 in.) 95 mm
(3.7 in.)
340 mm
(13.39 in.)
260.16 mm
(10.24 in.)

40.72 mm
45.76 mm
(1.6 in.)
(1.8 in.)

343.02 mm (13.51 in.)

64.1 mm (2.52 in.)

Figure 44. Countertop integration tray pattern with display and countertop cutout on right side

Note: Acquire the four mounting screws before you begin this installation.
1. For a free-standing unit, ensure that the four rubber feet
H are installed on
the bottom of the countertop integration tray (as shown in Figure 47 on page
73).
2. To secure the countertop integration tray to a countertop, perform the following
steps:
a. Detach the plastic fence from the countertop integration tray. To detach the
plastic fence:
1) Spread the rear sides away from the tray as shown in Figure 45.

Figure 45. Detaching the fence from the tray

2) Alternating from side to side, slide the plastic fence
B about 7 mm
(0.25 in.) until the plastic fence is detached from the metal integration
tray
A, as shown in Figure 46 on page 72.

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Mounting the Models 545 and 565

Figure 46. Sliding the fence off of the integration tray

b. Drill the four mounting holes and cut a hole in the countertop for cables, if
needed. Use Figure 44 on page 71 or the openings in the integration tray
as a pattern for drilling mounting holes and a cable opening in the counter.
See Figure 47 on page 73 for reference.
c. Remove the four rubber feet located on the bottom of the integration tray.
See Figure 47 on page 73 for the location of the feet.
d. Attach the integration tray to the countertop using four mounting screws,
one at each corner of tray. The four mounting screws are not provided with
the kit. Use 60-mm (0.25-in.), pan-head screws.
e. Reattach the fence to the integration tray.

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B
K

J F D

C
A
I

K E

H L

G
Figure 47. Overview of integration tray, SurePOS 500, printer, and filler panels

Table 16. Countertop integration tray legend

A Fence
G System filler panel

B SurePOS 500
H Four rubber feet

C Mounting plate
I Countertop integration tray

D 4610 SureMark Printer
J Small filler panel

E Mounting plate for 4610 SureMark
K Filler panel used when printer is
printer absent

F Center filler panel
L Filler panel used when printer is
present

3. Remove the rear cover as shown in “Rear cover removal” on page 30.
4. Attach small filler panel
J to the mounting plate
C.
5. Remove the base plate and place the unit on the mounting plate
C.

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Mounting the Models 545 and 565

6. Attach the SurePOS 500 and its mounting plate
C to the right side of the
integration tray
I as shown in Figure 47 on page 73. Slide the front of the
mounting plate under the appropriate pair of tabs on the tray and secure the
rear of the mounting plate to the tray with two thumbscrews.
7. Install the IBM 4610 SureMark Printer on the integration tray. Go to “Installing
IBM 4610 SureMark Models TF6 or TF7 printers” on page 91 for detailed
instructions on mounting plate installation and printer cable routing.
a. Attach the printer to its mounting plate as shown in Figure 66 on page 93.
b. Install the printer and the printer cables and route the cables as shown in
Figure 65 on page 93.
8. Connect the peripheral device cables to the appropriate ports on the rear
connector panel. Make the connections on the bottom row of the connector
panel first and work upward. Ensure that the cables are routed to the right of
the power cord.

Note: For a diagram of the port layout, see “Connectors, power, and
brightness controls” on page 5.
9. Use tie-wraps to secure cables to the cable-tie bar, if desired.
10. Replace the rear cover.
11. Plug the AC power cord into an AC outlet.
12. Replace the SurePOS 500 rear cover.
13. Install the filler panels after you route all the cables to your system.
a. Install the outer ends of the filler panels
L and
G into the integration
tray. Notice that the printer filler panel, shown on the right, is narrower than
the system filler panel. Also, the system filler panel has a bottom slot that
allows you to route the cables out the back.
b. Use the narrow filler panel
K to lock the filler panels together between
the system and the printer.

G
Figure 48. Connecting filler panels

Note: Depending on your desired configuration, you could have unused filler
panels.
14. Plug the system and printer AC power cords into an AC outlet.
15. After your installation is complete, press the printer power switch under the
printer cover to power On the printer.

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16. Switch ON the power to the SurePOS 500. Verify that the system is operating
correctly by checking the indicator lights (LEDs) on the front of the touch
screen.
17. Install your software. Refer to IBM SurePOS Model 545 and 565 Operating
System Installation Guide.

Installing filler panels without a printer

For systems without a printer:
1. Install the mounting plate in the center of the base using the removable
thumbscrews. See Figure 47 on page 73.
2. Install the system unit in the center using the mounting plate. Use system filler

G and
K.

Cash drawer
You can mount the SurePOS 500 on a full-size cash drawer by first installing an
integration tray on the cash drawer. Follow these steps:
1. To mount the integration tray onto the cash drawer:
a. Tilt the integration tray forward, and slide the tabs into the slots near the
front of the drawer. Lay the tray down on the cash drawer.
b. Attach the cash drawer integration tray to the cash drawer by tightening
two M6x8 screws
A at the rear of tray, as shown in Figure 49.

Figure 49. Attaching the integration tray to cash drawer

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Mounting the Models 545 and 565

2. To install the SurePOS 500 on an integration tray:

a. Remove the rear cover. “Rear cover removal” on page 30.
b. Remove the base plate. See “Base plate – removing and replacing” on
page 57.
c. Attach the system base to the mounting plate
B with the screws
C, as
shown in Figure 50.
d. Open the rear cash drawer cover
D by pushing in the two buttons located
on each side of the cash drawer. This provides access to the cash drawer
connector for cabling it to the system. You will also route cables inside the
cover through hole
E and to the system.

Figure 50. Attaching a mounting plate to center of cash-drawer integration tray

3. For installations without a printer, install the mounting plate in the center of
the base using the removable thumbscrews. Place the filler panels on both
sides. See Figure 47 on page 73. Install rear system panel
G first and use
filler panels
K to lock in filler panel
G onto the tray.
4. Install the IBM 4610 SureMark printer on the integration tray with the SurePOS
500. Go to “Installing IBM 4610 SureMark Models TF6 or TF7 printers” on
page 91 for detailed instructions on printer cable routing, RS-232 printer switch
settings, and mounting plate installation:

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 Mounting the Models 545 and 565

a. Plug the data and power cables into the printer, routing the data cable,
under the cable tie bar and toward the rear connector panel as shown in
Figure 65 on page 93.
b. Attach the SurePOS 500 Models 545 and 565 base mounting plate
A to
the right side of the integration tray. Slide the front of the plate under the
appropriate pair of tabs on the integration tray. Secure the rear of the plate
to the tray with two thumbscrews as shown in Figure 51.

Figure 51. Attaching mounting plate to the cash drawer integration tray

c. Attach the printer
B to the printer base mounting plate by sliding it onto
the two tabs until it locks in place.
d. Attach the printer base mounting plate
C to the integration tray. Slide the
front of the plate under the appropriate pair of tabs on the integration tray.
Secure the rear of the plate to the tray with two thumbscrews.
5. Plug the cash-drawer cable into the cash drawer and route it under the
cable-tie bar to the rear connector panel.
6. Plug the data and power cables into the printer, routing the data cable under
the cable tie-bar and toward the rear connector panel.

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Mounting the Models 545 and 565

7. Route all cables through the hole at the center rear of the cash drawer. Then
route the cables through the rear of the system, laying them flat on top of the
cash-drawer integration tray.
8. If you are installing a distributed-character display or an all points addressable
(APA) display, see “Mounting a distributed customer display and APA display to
a cash drawer” on page 89.
9. Connect the peripheral cables to the appropriate ports on the rear connector
panel. See “Connectors, power, and brightness controls” on page 5.

Note: If you are installing a distributed-character display, route the cable

through the unattached rear modesty panel
C in Figure 52 on page
79.
10. Use tie-wraps to secure cables to the cable-tie bar. Be sure to run cables to
the right of the power cable when viewed from the rear.
11. Replace the rear cover.
12. See Figure 52 on page 79. Install the filler panels after you route all the cables
to your system. Note that filler panel
A locks filler panels
B onto the tray.
Install the filler panels after you have routed all of the cables.
a. Install the outer ends of the filler panels
B into the integration tray. Notice
that the printer filler panel, shown on the right, is narrower than the system
filler panel. Also, the system filler panel has a bottom slot that allows you to
route the cables out the back.
b. Use the narrow filler panel
A to lock the filler panels together between
the system and the printer.

Note: Depending upon your desired configuration, you could have unused
filler panels.
13. Tilt the modesty cover
C so the front hooks attach to the tray; then push
down until the cover snaps into place.

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Figure 52. Attaching filler panels and the rear modesty cover

14. Attach the distributed customer display
D to the cash drawer with two
thumbscrews
F and snap the entire unit into place at the rear of the tray.
15. Close the cash-drawer rear cover.
16. Plug the AC power cords for the printer and the system into an AC outlet.
17. After your installation is complete, press the printer power switch under the
printer cover to power on the printer.
18. Switch ON the power to the SurePOS 500. Verify that the system is operating
correctly by checking the indicator lights (LEDs) on the front of the system.
19. Install your software. Refer to IBM SurePOS Model 545 and 565 Operating
System Installation Guide.

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Mounting the Models 545 and 565

Keyboard-integration tray
This section describes how to install a keyboard tray with the SurePOS 500 Models
545 and 565.

Countertop and full-size cash drawer

Figure 53. Full-size keyboard-integration tray on a countertop

The full-size keyboard-integration tray can be used as a free-standing unit, secured

to a countertop using mounting screws or mounted to a cash drawer. The SurePOS
500 is mounted with the 4610 SureMark printer using the full-size
keyboard-integration tray.

Important
Devices such as the printer, integrated character display, and keyboard are
mounted the same way when the full-size keyboard-integration tray is used for
a countertop or cash drawer mount. Therefore, the instructions for the
countertop and cash drawer mount have been combined.

Mounting the integration tray to a countertop

Use the countertop keyboard-integration tray as a pattern for drilling the four
mounting holes and for the cable opening, if you plan to route the cables through
the countertop.

Note: Four screws (not provided) are required to mount the integration tray to a
countertop.
1. Prepare the SurePOS 500 to mount to the keyboard-integration tray:
a. Remove the rear cover.

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Notes:
1) If you are routing cables underneath the counter, route them through
the cable-access hole in the counter.
2) If you are routing cables on top of the counter, route them out the back
of the system. Lay them flat along the countertop.
2. For a free-standing unit, ensure that the four rubber feet
A are installed on
the bottom of the countertop keyboard integration tray (as shown in Figure 54
on page 82).
3. To secure the full-size keyboard-integration tray to a countertop, perform
the following steps:
a. Remove the fence
E from the countertop keyboard-integration tray by
removing the screws as shown in Figure 54 on page 82.
b. Drill the four mounting holes and cut a hole in the countertop for cables if
needed. Use the openings in the integration tray as a pattern for drilling
mounting holes and a cable opening in the counter.
c. Remove the rubber feet
A located on the bottom of the integration tray.
See Figure 54 on page 82 for location of feet.
d. Attach the keyboard-integration tray to the countertop using four mounting
screws, one at each corner of tray. The four mounting screws are not
provided with the kit. Use 60-mm (0.25-in.) pan-head screws.
e. Reattach the fence
E to the tray with the six small screws.

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Mounting the Models 545 and 565

Figure 54. Countertop keyboard-integration tray assembly

Table 17. Countertop integration tray legend

A Four rubber feet
D Mounting plate

B Keyboard-integration tray
E Fence

C Insulator plate

4. Prepare the SurePOS 500 to mount to the keyboard-integration tray:

a. Remove the rear cover.
Notes:
1) If you are routing cables underneath the counter, route them through
the cable-access hole in the counter.
2) If you are routing cables on top of the counter, route them out the back
of the system. Lay them flat along the countertop.

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5. Remove the rear cover on the cash drawer. While pressing in on the two
buttons located on the sides of the cash drawer, pull back on the rear cover
back to remove it. Discard this rear cover. A new rear cover is used for
installation of the keyboard integration kit.
6. Install the keyboard-integration tray on a cash drawer:

E
D

A
C
Figure 55. Installing the keyboard-integration tray on a cash drawer

a. Tilt the integration tray down so the three tabs
B align with the three tab
holes
C on the cash drawer as shown in Figure 55. Set the integration
tray down on the cash drawer while aligning the screw holes
D with holes
on the cash drawer.
b. Secure the integration tray to the cash drawer with two screws at location

D.
7. Attach the mounting plate
F to the integration tray with four plastic washers
and screws as shown in Figure 55.
8. Attach the fence
G to the integration tray with six small screws.
9. Remove the base plate. See “Base plate – removing and replacing” on page
57.
10. Attach the SurePOS 500 to the mounting plate as shown in Figure 56 on page
84. Slide the unit from the back toward the front until the frame fits into the

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Mounting the Models 545 and 565

tabs
B, and the screws
A and mounting holes
C are lined up. Tighten the
two base-bracket screws.

Figure 56. Installing the SurePOS 500 onto the integration tray

11. Install the IBM 4610 SureMark printer on the integration tray, by performing the
following steps:

Note: See the 4610 SureMark Point-of-Sale Printers User’s Guide for detailed
information about switch settings and cabling for the printer.

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Figure 57. Installing the 4610 printer onto the integration tray

Table 18. 4610 SureMark printer on a full-size keyboard-integration tray legend

A Printer stand for the 4610 Models TF6 and TF7 printers

B 4610 Models TF6 and TF7 printers (small footprint)

C 4610 Models TG3, TG4 and TG5 printers

a. Install the printer cables and route the cables as shown in Figure 65 on
page 93.
v For the small-footprint 4610 SureMark Models TG3, TG4 and TG5
printers
B, first insert the plastic printer base
A onto the integration
tray and then place the printer into the printer base.
v For the large-footprint 4610 SureMark Model TG3 and TG4 printers,
place the printer directly onto the integration tray.
12. To install the keyboard, perform the following steps. See Figure 58 on page 86
for callout locations:

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Mounting the Models 545 and 565

Figure 58. Installing the keyboard onto the integration tray

a. Attach the keyboard cable
A to the IBM PS/2® port on the rear connector
panel.
b. Place the keyboard on the integration tray while pushing the excess
keyboard cable back under the filler panel.
13. Prepare the distributed customer display to be installed on an integration tray.
a. Route the distributed customer display cable through the mounting post
(and post extension, if used) and plug the cable into the display.

Figure 59. Attaching the distributed customer display cable

b. Attach the character display’s top to its post by pressing the display down
on the post until it snaps into place.
14. To install a distributed customer display or an APA display, perform the
following steps:

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Figure 60. Installing the distributed customer display onto the integration tray

a. Route the display cable
F through hole
D, as shown in Figure 60. You
might need to place the display on its side to connect the display cable to
the system unit rear connector panel.
b. Route the display cable to the rear connector panel, passing it under the
cable-tie bar, and plug it into the 15-pin serial connector.
c. Attach the distributed customer display
A to the cash drawer at location

B with two thumbscrews
C.
15. Plug the AC power cord to the power supply.
16. Connect the peripheral cables to the appropriate ports on the SurePOS 500
rear connector panel. Make the connections on the bottom row of the panel
first and work upward. See “Connectors, power, and brightness controls” on
page 5.
Notes:
a. If you are routing the cables under the counter, route all cables (including
the AC power cord) through the cable-access hole.
b. If you are routing the cables on top of the counter, route all cables out the
rear of the system. Lay the cables flat along the countertop.
17. Use tie-wraps to secure cables to the integration tray.
18. Replace the rear cover and install the rear filler panel.
19. Attach the cash-drawer rear cover by aligning the tabs with the buttons, and
push in on the cover.
20. Plug the system and printer AC power cords into an AC outlet.
21. After your installation is complete, press the printer power switch under the
printer cover to power on the printer.

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Mounting the Models 545 and 565

22. Switch ON the power and verify that the system is operating correctly by
checking the indicator lights (LEDs) on the front of the touch screen.
23. Install your software. Refer to IBM SurePOS Model 545 and 565 Operating
System Installation Guide.

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 Mounting the Models 545 and 565

Installing additional peripheral devices

Attention: Before you use the following procedures to install additional peripheral
devices, see “Safety Information” on page xi.

Mounting a distributed customer display and APA display to a cash

drawer
The SurePOS 500 Models 545 and 565 provides a powered, 15-pin, serial port for
attaching a distributed customer display, APA character-graphic display, or other
device requiring a powered serial connection. The SurePOS 500 Models 545 and
565 distributed customer display is mounted behind the cash-drawer modesty
panel. It can also be mounted to a countertop with customer-provided hardware.
Use these instructions to mount a character display to a cash drawer.
1. Prepare the system for installation of the distributed customer display.
a. Switch OFF the power at the system unit.
b. Remove the SurePOS 500 Models 545 and 565 rear cover (see “Rear cover
removal” on page 30) to access the rear connector panel.
2. Prepare the distributed customer display to be installed on an integration tray.
a. Route the distributed customer display cable through the mounting post (and
post extension, if used) and plug the cable into the display, as shown in
Figure 61.

Figure 61. Attaching the distributed customer display cable

b. Attach the character display top to its post by pressing the display down on
the post until it snaps into place.
3. Go to the appropriate procedure for a non-keyboard integration tray or keyboard
integration tray to complete the installation of the distributed customer display:
v For installation of a distributed customer display on a non-keyboard
integration tray, go to Step 4 on page 90.
v For installation of a distributed customer display on a keyboard integration
tray, go to Step 5 on page 91.

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Mounting the Models 545 and 565

4. To install a distributed customer display
D on a non-keyboard integration tray,

perform the following steps:
a. Remove the filler panels
A and
B (two) and the rear modesty panel
C
from the integration tray, as shown in Figure 62.

Figure 62. Attaching the distributed customer display to the system unit

b. Remove one of the two plugs
E in the rear modesty panel. Figure 62
shows one plug removed.
c. Route the character display cable through the hole in the modesty panel.
You may need to lay the display on its side to connect the display cable to
the rear connector panel.
d. Route the character display cable to the rear connector panel. Plug it into
the 15-pin serial connector.
e. Reinstall the rear cover of the SurePOS 500 Model 514 (see “Rear cover
removal” on page 30).
f. Reinstall the filler panels
B, and then install
A, as shown in Figure 62.
g. Attach the post, through the modesty cover
C to the cash drawer with 2
thumbscrews
F. Snap the entire unit into place at the rear of the tray.

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5. To install a distributed customer display on a keyboard integration tray, perform

the following steps:
a. Route the character display cable through the hole behind mounting post as
shown in Figure 63. You might need to lay the display on its side to connect
the display cable to the system unit rear connector panel.

Figure 63. Installing the distributed customer display onto the keyboard integration tray

b. Route the distributed customer display cable
F to the rear connector
panel, passing it under the cable-tie bar. Plug it into the 15-pin serial
connector.
c. Attach the distributed customer display
A to the cash drawer mounting
post with two thumbscrews
C. Snap the entire unit into place at the rear of
the tray, as shown in Figure 63.

Installing IBM 4610 SureMark Models TF6 or TF7 printers

Note: Service for the IBM SurePOS Model 4951, Model 514 includes the IBM 4610
SureMark printer.

The IBM 4610 SureMark Model TF6 and TF7 (4610 TF6 or TF7) are the smaller
4610 models that contain only a thermal customer receipt station. These models do
not support document printing. For detailed information about these printers, see
the IBM 4610 SureMark Point-of-Sale Printers User’s Guide.

The 4610 TF6 or TF7 can be installed as a freestanding unit, attached to a

countertop integration tray, or attached to a cash drawer integration tray. Attaching
the 4610 TF6 or TF7 to a non-keyboard integration tray is different than attaching it
to a keyboard integration tray:
v For the non-keyboard integration tray, the 4610 TF6 or TF7 is attached to a
mounting plate and then attached to the non-keyboard integration tray.

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Mounting the Models 545 and 565

v For the keyboard integration tray, the 4610 TF6 or TF7 is set into a plastic printer
base and then set on the keyboard integration tray.

Figure 64 shows the 4610 TF6 or TF7 printer connectors.

A
B
C
E
D

Figure 64. 4610 TF6 or TF7 printer connector locations

A Power supply port (RS-232 only)
D Cash drawer connector

B RS-232 port or Powered USB port
E RS-232 mode switch

C (Not used on the SurePOS 500 Models
545 and 565)

To install the 4610 TF6 or TF7 printer, perform the following steps:
1. Switch OFF the power at the system unit.
2. Remove the SurePOS 500 rear cover (see “Rear cover removal” on page 30).
3. Check the printer RS-232 mode-switch setting for the printer. It is near the rear
cable connections. See
E in Figure 64 for switch location. For switch settings,
see the IBM 4610 SureMark Point-of-Sale Printers User’s Guide.
4. Connect and route the RS-232 communication cable or Powered USB cable
A
and the power supply cable
B as shown in Figure 65 on page 93.

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 Mounting the Models 545 and 565

Figure 65. Attaching and routing the cables to the printer.

5. Connect any other signal cables for I/O devices to the correct ports.
6. If you are installing a freestanding printer, route the cables to the rear connector
panel on the SurePOS 500 Models 545 and 565 system unit. Pass the cables
under the cable-tie bar, and plug it into one of the standard serial ports.
7. Go to the appropriate procedure for non-keyboard integration tray or keyboard
integration tray mounting of the 4610 TF6 or TF7 printer:
v If you are installing a 4610 TF6 or TF7 printer on a non-keyboard integration
tray, continue with Step 8.
v If installing a 4610 TF6 or TF7 printer on a keyboard integration tray, continue
with Step 11 on page 84.
8. To install a 4610 TF6 or TF7 printer on a non-keyboard integration tray, perform
the following steps:
a. Attach the printer mounting plate to the bottom of the printer. The mounting
plate slides into the two bottom slots of the printer.

Figure 66. Attaching the 4610 TF6 or TF7 printer mounting plate for a non-keyboard
integration tray

b. The procedure for mounting the printer to a non-keyboard integration tray is

the same for countertop or cash drawer. With the mounting plate attached to
the printer, slide the front of the printer mounting plate into the slots located

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Mounting the Models 545 and 565

toward the front of the integration tray. Secure the printer by tightening the
two thumbscrews on the mounting plate to the tray.
c. Route the RS-232 cable
A to the rear connector panel of the system unit
as shown in Figure 67. Plug it into one of the three standard serial ports on
the system unit.
d. Route the printer power cord
B toward the system and out through the
hole in the integration tray, as shown in Figure 67.

Note: When routing the printer and power cables, make sure that the
cables are routed inside the mounting plate screws to enable correct
installation of the filler panels.

A B

Figure 67. 4610 TF6 or TF7 cable routing

94 Models 545 and 565 Hardware Service Guide

Appendix A. Field replaceable parts
How to use the FRU catalog . . . . . . . . . . . . . . . . . . . . 95
Assembly 1: Models 545 and 565 . . . . . . . . . . . . . . . . . . 96
Assembly 2: Countertop and cash drawer keyboard integration tray and filler
panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Assembly 3: Optional peripherals . . . . . . . . . . . . . . . . . . 100
Assembly 4: Countertop non-keyboard integration tray and filler panels . . . . 102
Assembly 5: Cash drawer non-keyboard integration tray and filler panels 104

This chapter contains field-replaceable part number information the SurePOS 500
Models 545 and 565.

How to use the FRU catalog

This parts listing contains reference drawings and a corresponding index for all field
replaceable parts. The index provides the part number, the quantity required (units),
and a description of the part.

Listed below is additional information about the parts assembly index.

SIMILAR ASSEMBLIES
If two assemblies contain a majority of identical parts, they are broken down
on the same list. Common parts are shown by one index number. Parts
specific to one or the other of the assemblies are listed separately and
identified by description.
AR (As Required) in the Units column indicates that the quantity is not the
same for all machines.
NP (Non-Procurable) in the Units column indicates that the part is
non-procurable and that the individual parts or the next higher assembly
should be ordered.
NR (Not Recommended) in the Units column indicates that the part is
procurable, but not recommended for field replacement, and that the next
higher assembly should be ordered.
R (Restricted) in the Units column indicates the part has a restricted
availability.
INDENTURE
The indenture is marked by a series of dots located before the parts
description. The indenture indicates the relationship of a part to the next
higher assembly.
No Dot Main assembly
One Dot Detail parts of a main assembly
One Dot Subassembly of the main assembly
Two dots Detail part of a one-dot subassembly
Two dots Subassembly of a one-dot subassembly
Three dots Detail part of a two-dot subassembly

© Copyright IBM Corp. 2006 95

Field-replaceable parts

Assembly 1: Models 545 and 565

1

4
5
6

7
8
9
10

11

12

13

14

15
16
17
18

19

20

21

22

23

24
25
26
27

28
96 Models 545 and 565 Hardware Service Guide
 Assembly 1: (continued)

Asm– Part
Index Number Units Description
1–1 42V3886 Front bezel assembly, 12 in.
–1 42V3887 Front bezel assembly, 15 in.
–2 12X1000 Tablet assembly, 12 in.
–2 12X1001 Tablet assembly, 15 in.
–3 42V3889 LCD assembly, 12 in.
–3 42V3890 LCD assembly, 15 in.
–4 42V3897 MSR hole plug
–5 42V3893 Touch cable door, 12 in.
–5 42V3894 Touch cable door, 15 in.
–6 42V3892 Operator card kit, 12 in.
–6 12X1036 Operator card kit, 15 in.
–7 42V3924 Top, center cover kit
– 41D0171 Power button cover
–8 42V3937 Processor fan/fan bracket
–9 42V3925 Hinge cover, 12 in. and 15 in.
– 42A3641 HDD
– 42V3944 HDD cable kit
–10 42V3922 Hinge, 12 in. and 15 in.
–11 42V3927 HDD cover with speaker
–11 42V3928 HDD cover, no speaker
–12 42V3943 HDD assembly (HDD, bracket, 4 screws)
– 42V3980 HDD bracket
–13 42V3931 Side cover kit
–14 42V3950 PC card door
–15 42V3953 Audio port cover
–16 42V3930 Speaker ESD shield
–17 42N5755 Speaker
–18 42V3945 Tablet cable, 12 in. and 15 in.
–19 42V3936 HDD fan kit (bracket, fan, cable)
– 42V3969 System board tray
–20 42V3948 Planar assembly, no audio, no PCMCIA
–20 42V3949 Planar assembly, audio, PCMCIA
–21 42V3938 Processor heat sink
– 42V3939 Processor 2.53 GHz
–22 12X1009 Video card
–23 12X1110 Rear cover
–24 42V3935 Tailgate assembly
– 42V3947 Speaker extension cable
–25 42V3932 Cable tie bar
–26 42V3933 Power supply latch arm
–27 42V3682 Power supply
– 42V3951 Power supply EMC shield
–28 42V3940 Base, 12 in. and 15 in.
– 45P6222 Battery
– 42V3952 Screw kit
– 42V3956 Memory, 512 MB
– 42V3957 Memory, 1 GB
– 41D9746 USB memory key

Appendix A. Field replaceable parts 97

Field-replaceable parts

Assembly 2: Countertop and cash drawer keyboard integration tray

and filler panels

98 Models 545 and 565 Hardware Service Guide

 Assembly 2: (continued)

Asm– Part
Index Number Units Description
2– Countertop and cash drawer keyboard integration tray and filler panels
–1 41D0214 1 FRU, plate/fence ASM, wide cash drawer or countertop (includes hardware)
– 1 v ASM, wide cash drawer plate (includes hardware)
– 1 v - M6X8 screws, cash drawer mount
– 1 v - Fence, wide
– 1 v - M3X5 screws, fence mounting
– 1 v - Feet, rubber
–2 42V3964 1 FRU, plate ASM, terminal mounting
– 1 v ASM, terminal mount
– 1 v - Plate, terminal mount insulator
– 1 v - Washer, insulating
– 1 v - M6X12 screws, terminal mount
–3 42V3965 5 FRU, filler panels, wide and countertop
– 1 v Cover, keyboard filler, retail keyboard
– 1 v Cover, terminal filler, wide tray and countertop
– 1 v Cover, wide CD rear curtain
– 1 v Fence, plug
–4 47P9273 1 FRU, iron gray printer footprint adapter, SST to 4610
– 1 v ASM, iron gray printer footprint adapter
– 1 v - Base, SST to 4610 footprint, iron gray
– 1 v - Panel, SST to 4610 footprint, iron gray
– 1 v - Feet, printer base
– 41D0216 1 FRU, retail integration, installation hardware kit (not shown)
– 1 v Hardware kit, retail integration
– 1 v - M3X5 screws, fence mounting (6)
– 1 v - M5X10 screws, system unit mounting (4)
– 1 v - M6X12 screws, terminal mounting (4)
– 1 v - Washer, insulation (for terminal mount screws) (4)
– 1 v - M6X8 screws, CD plate mounting (4)
– 1 v - Feet, CD plate countertop mounting (5)
– 14R0157 Wide keyboard filler panel

Appendix A. Field replaceable parts 99

Field-replaceable parts

Assembly 3: Optional peripherals

100 Models 545 and 565 Hardware Service Guide

 Assembly 3: (continued)

Asm– Part
Index Number Units Description
3–1 42V3960 MSR, 3-track
–1 42V3961 MSR, JUCC
–2 42N5755 Speaker
–3 42V3958 Display, integrated 2x20
–4 42V3959 VFD housing, integrated

Appendix A. Field replaceable parts 101

Field-replaceable parts

Assembly 4: Countertop non-keyboard integration tray and filler panels

4 4

3
1

6
2

4
5

102 Models 545 and 565 Hardware Service Guide

 Assembly 4: (continued)

Asm– Part
Index Number Units Description
4– Countertop non-keyboard integration tray and filler panels
–1 41D0261 Plate/fence assembly, counter top mounting
–2 41D0211 Plate assembly, printer mounting
–3 42V3966 Plate assembly, terminal mounting (includes screw)
–4 42V3967 Filler panel kit
–5 Feet, rubber (5), included in Hardware kit
–6 12X1129 Printer filler panel kit for non-keyboard trays
– 41D0212 Hardware, non-keyboard integration tray (kit - includes feet and screws, not
illustrated)
–
–

Appendix A. Field replaceable parts 103

Field-replaceable parts

Assembly 5: Cash drawer non-keyboard integration tray and filler

panels

4 5
2

104 Models 545 and 565 Hardware Service Guide

 Assembly 5: (continued)

Asm– Part
Index Number Units Description
5– Cash drawer non-keyboard integration tray and filler panels
–1 41D0210 1 Plate and fence, cash drawer mount
–2 41D0211 1 Plate, printer mounting
–3 42V3966 1 Plate, terminal mounting
–4 42V3967 1 Panels, filler
–5 20P0308 1 Cover, modesty (and 2 plugs)
–6 12X1129 1 Printer filler panel kit, non-keyboard
– 41P0212 1 Hardware, non-keyboard integration tray (kit - includes screws, not illustrated)
–
–

For power cords see Appendix B, “Power cords,” on page 107.

Appendix A. Field replaceable parts 105

106 Models 545 and 565 Hardware Service Guide
Appendix B. Power cords
Table 19. Power cord lengths and part numbers by country
Part number Length Country
39M5066 4.3 m Argentina
39M5093 4.3 m Bahamas, Barbados, Bermuda, Bolivia,
Canada, Cayman Islands, Columbia, Costa
Rica, Dominican Rep., El Salvador, Ecuador,
Guatemala, Haiti, Honduras, Jamaica, Mexico,
Netherlands Antilles, Nicaragua, Panama,
Peru, Philippines, U.S., Venezuela
39M5100 4.3 m Australia, New Zealand
39M5204 4.3 m China (PR)
39M5211 4.3 m Korea
39M5121 4.3 m Europe
39M5128 4.3 m Denmark
39M5142 4.3 m South Africa
39M5149 4.3 m United Kingdom, Hong Kong
39M5156 4.3 m Switzerland
39M5163 4.3 m Chile, Italy
39M5170 4.3 m Israel
39M5191 4.3 m Japan
39M5079 4.3 m (non-locking) United States
39M5077 1.8 m United States, Chicago
39M5107 4.3 m (locking) United States

© Copyright IBM Corp. 2006 107

Power cords

108 Models 545 and 565 Hardware Service Guide

Appendix C. System specifications and planning information
Physical specifications and dimensions . . . . . . . . . . . . . . . 110
Dimensions with trays . . . . . . . . . . . . . . . . . . . . . 110
Dimensions of unit with 12-inch display . . . . . . . . . . . . . . 113
Dimensions of unit with 15-inch display . . . . . . . . . . . . . . 114
Power requirements and consumption . . . . . . . . . . . . . . . . 115
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Port power ratings . . . . . . . . . . . . . . . . . . . . . . 115
Connector-pin assignments . . . . . . . . . . . . . . . . . . . . 116
External connectors . . . . . . . . . . . . . . . . . . . . . . 116
Speaker connector . . . . . . . . . . . . . . . . . . . . . 116
MSR connector . . . . . . . . . . . . . . . . . . . . . . 116
USB port connectors . . . . . . . . . . . . . . . . . . . . 118
Keyboard connector . . . . . . . . . . . . . . . . . . . . 118
Mouse connector . . . . . . . . . . . . . . . . . . . . . . 119
Microphone connector . . . . . . . . . . . . . . . . . . . . 119
Headphone connector . . . . . . . . . . . . . . . . . . . . 119
Serial connectors . . . . . . . . . . . . . . . . . . . . . 120
Ethernet connector . . . . . . . . . . . . . . . . . . . . . 121
External video connector . . . . . . . . . . . . . . . . . . . 122
Cash drawer connector (2) . . . . . . . . . . . . . . . . . . 123
Integrated customer display connector . . . . . . . . . . . . . . 123
Temperature, humidity, and altitude limits . . . . . . . . . . . . . . . 124

This appendix provides information on power subsystems, and environmental

requirements.

© Copyright IBM Corp. 2006 109

System specifications and planning information

Physical specifications and dimensions

The SurePOS 500 Series physical specifications are described in Table 20.
Table 20. Height, weight and depth of the SurePOS 500 Models 545 and 565
Height: Tablet Height Depth: Tablet Depth: Tablet
4846 Weight Width
at 15 degrees maximum at 15 degrees at 60 degrees
Tower 11.3 kg (25 lbs) 357.9 mm (14.0 374.1 mm (14.7 316.8 mm (12.5 385.8 mm (15.2 307.9 mm (12
and 12-in. in.) in.) in.) in.) in.)
tablet
Tower 12.2 kg (27 lbs) 381.8 mm (15.0 393.6 mm (15.5 324.4 mm (12.8 405.8 mm (15.9 369 mm (14.5
and 15-in. in.) in.) in.) in.) in.)
tablet

Table 21. Weights of integrated, distributed displays and MSR

Component Weight
Integrated 2x20 display 0.2 kg (0.38 lbs)
Distributed 2x20 display 0.5 kg (1.2 lbs)
Distributed APA display 0.7 kg (1.6 lbs)
MSR (three-track or JUCC) 0.16 kg (0.41 lbs)

Dimensions with trays

Table 22 provides the dimensions shown by measurements A and B in Figure 68 on
page 111, Figure 69 on page 111, and Figure 70 on page 112.

Note: The tablet is shown at 15 degrees.

Table 22. SurePOS 500 Models 545 and 565 dimensions. See Figure 68 on page 111 and Figure 69 on page 111 to
locate Measurement A and B
Product with 12 in. tablet and the
Measurement A Measurement B
following:
Counter top tray 382.4 mm (15.1 in.) 478.6 mm (18.8 in.)
Cash drawer tray 493.5 mm (19.4 in.) 480.9 mm (18.9 in.)
Retail tray 527.4 mm (20.8 in.) 489.2 mm (19.2 in.)
Product with 15 in. tablet and the following:
Counter top tray 406.2 mm (15.9 in. ) 509.2 mm (20.0 in.)
Cash drawer tray 517.3 mm (20.4 in.) 511.4 mm (20.1 in)
Retail tray 551.1 mm (21.7 in.) 519.7 mm (20.5 in.)

110 Models 545 and 565 Hardware Service Guide

 System specifications and planning information

31.2mm (1.2 in.)

39.6mm (1.5 in.)

43.9mm (1.7 in.)

491.5mm (19.3 in.)

428mm (17.7 in.)
A
7.2mm (.28 in.)

449.5mm (17.7 in.)

B
523.9mm (20.6 in.)

Figure 68. Dimensions of SurePOS Models 545 and 565 with retail tray. The tablet is shown at 15 degrees.

39.6mm (1.5 in)

31.2mm (1.2 in.)

346.6mm (13.6 in)

A

43.9mm (1.7 in.)

441.9mm (17.4 in.)

340.5mm (13.4 in)

B
356.2mm (14.0 in.)

Figure 69. Dimensions of SurePOS Models 545 and 565 with counter top tray. The tablet is shown at 15 degrees.

Appendix C. System specifications and planning information 111

System specifications and planning information

31.23mm (1.2 in.)

39.6mm (1.5 in.)

415.4mm (17.7 in.)

457.65mm (18.0 in.)
A
43.9mm (1.7 in.)

3.4mm (.13 in.)

449.5mm (17.7 in.)

Figure 70. SurePOS Models 545 and 565 with cash drawer tray. The tablet is shown at 15 degrees.

112 Models 545 and 565 Hardware Service Guide

 System specifications and planning information

Dimensions of unit with 12-inch display

201.6mm (7.94 in.)

212mm (8.35 in.)

31.2mm (31.2 in.)
357.9mm (14.09 in.)

389.1mm (15.32)
362mm (14.25 in.)
322.1mm (12.68 in.)

212mm (8.35 in.)

242.3mm (9.54 in.)

307.9mm (12.1 in.) 228.2mm (8.98 in.)

15° 247.7mm (9.75 in)
351.8mm (13.9 in.)
316.8mm (12.5 in.)

Figure 71. Dimensions of unit with 12-inch display

Appendix C. System specifications and planning information 113

System specifications and planning information

Dimensions of unit with 15-inch display

201.6mm (7.94 in.)

212mm (8.35 in.)

30.6mm (1.2in)

412.4mm (16.24 in.)

362mm (14.25 in.
381.8mm (15.03 in.)

322.1mm (12.68 in.)

212mm (8.35 in.) 228.2mm (8.98 in.)

242.3mm (9.54 in.)
15° 247.6mm (9.75 in.)
369mm (14.5 in.)
324.4mm (12.77 in.)

Figure 72. Dimensions of unit with 15-inch display

114 Models 545 and 565 Hardware Service Guide

 System specifications and planning information

Power requirements and consumption

This section describes the power requirements and power consumption of the
SurePOS 500 Series.

Power
Table 23. Input voltage, frequency
Input Frequency
100 – 127 V AC 50 or 60 Hz
200 – 240 V AC 50 or 60 Hz

Table 24. SurePOS 500 Series Models 545 and 565 power supply
Nominal output voltage Tolerance Rated Current
+5.0 V AUX ±5% 2.0 A
+5.0 V MAIN +5/-4% 8.0 A
+12.0 V ±5% 12.0 A
+3.3 V ±5% 6.0 A
-12.0 V ±10% 0.3 A
+25.3 V ±4% 3.0 A

Table 25. Power consumption

State: Usage:
Off 4W
Standby 80 W
Suspend Not supported
On (idle, no I/O) 120 W
On (idle, I/O: cash drawer, MSR, 2/20, 125 W
printer)
On (max, printing) 170 W
Input 100 - 127, 200 - 240 V AC (nominal), 50 or
60 Hz (+/- 3 Hz)
Voltage/Frequency Sinusoidal, trapezoidal, or square wave
inputs
Maximum kVA 0.3
AC Input IEC 320 C14, unshielded right angle type
Connector/Cable leakage current 3.5 ma maximum
Inrush < 30 A (peak, first cycle)

Port power ratings

v Only one cash drawer may be activated at any instance in time.
v Hot plugging of powered USB devices, especially printers, is not supported.
Some powered USB devices create surge currents that may cause the system
power supply to initiate over-current shut down.

Note: All ports provide protection against power surges.

Appendix C. System specifications and planning information 115

System specifications and planning information

Table 26. Port current ratings

Port / name Port Current Ratings Maximum current
Distributed VFD/Serial 5V 0.95A
12V 0.65A
USB (x6) 5V 0.5 A
USB Plus Power 5V 0.5 A
12V 1.5 A
24V 3.0 A continuous
5.0 A peak
Keyboard and Mouse 5V 0.6 A

Connector-pin assignments
This following sections list the connector-pin assignments for the external and
internal connectors.

External connectors
The following sections show the connector-pin assignments for external connectors.

Speaker connector

5 1

Table 27. Speaker connector-pin assignments

Pin Connect
1 +12 V AC
2 Ground
3 Line Left
4 Line Right
5 Ground

MSR connector

8 1

Table 28. MSR connector-pin assignments

Pin Connector
1 +5 V dc
2 Serial data out
3 Serial data in
4 Ground

116 Models 545 and 565 Hardware Service Guide

 Connector-pin assignments

Table 28. MSR connector-pin assignments (continued)

Pin Connector
5 KBD enable
6 Keyboard data
7 Keyboard clock
8 Ground

Appendix C. System specifications and planning information 117

Connector-pin assignments

USB port connectors

1 2 3 4

Table 29. USB port connector-pin assignments

Unpowered USB
Pin Connector
1 5 V bus
2 −Data
3 +Data
4 Ground

Note: Tablet USB ports are USB 1.1 compliant; side and back USB ports are USB
2.0 compliant.
Table 30. USB port connector-pin assignments
Powered USB
Pin Connector
Shell Shield
1 5 V Vbus
2 −Data
3 +Data
4 Ground
5 Ground
6 Vplus (12 V or 24 V)
7 Vplus (12 V or 24 V)
8 Ground

Keyboard connector

6 5

4 3

2 1
118 Models 545 and 565 Hardware Service Guide
 Connector-pin assignments

Table 31. Keyboard and mouse connector-pin assignments

Pin Signal I/O Pin Signal I/O
1 Keyboard data I/O 4 +5 V Main I/O
3 Ground 5 Keyboard clock

Mouse connector

6 5

4 3

2 1
Table 32. Keyboard and mouse connector-pin assignments
Pin Signal I/O Pin Signal I/O
2 Mouse data I/O 4 +5 V Main I/O
3 Ground 6 Mouse clock

Microphone connector
The microphone connector is on the tower, at the lower left, below the side
connector panel.
Ground
Signal
5v

Table 33. Microphone connector-pin assignments

Pin Signal
Tip Signal
Ring +5 V dc
Base Ground

Headphone connector
The headphone connector is on the tower, at the lower left, below the side
connector panel, with the microphone connector.
Table 34. Headphone connector-pin assignments
Pin Signal
Tip Left channel audio

Appendix C. System specifications and planning information 119

Connector-pin assignments

Table 34. Headphone connector-pin assignments (continued)

Pin Signal
Ring Right channel audio
Base Ground

Serial connectors
RJ-45 Connectors (3):

8 1

Table 35. RJ-45 connector-pin assignments

Pin Signal Pin Signal
1 DSR 5 RXD
2 CD 6 TXD
3 DTR 7 CTS
4 Ground 8 RTS

120 Models 545 and 565 Hardware Service Guide

 Connector-pin assignments

15-pin serial connector: The 15-pin serial connector is a female connector.

8 1

15 9

Table 36. Assignments for 15-pin serial connector

Pin Connector Pin Connector
1 Carrier detect 8, 9 +12 V dc at 0.5 A
maximum
2 Receive data 11 Distributed display present
3 Transmit data 12 Data set ready
4 Data terminal ready 13 Request to send
5 Ground 14 Clear to send
6 Ground 15 Ring indicate
7, 10 +5 V dc at 0.5 A maximum

Ethernet connector

8 1

Table 37. Ethernet connector-pin assignments

Pin Signal I/O Pin Signal I/O
1 TxD+ O 5 Ground
2 TxD− O 6 RxD− I
3 RxD+ I 7 Ground
4 Ground 8 Ground

Appendix C. System specifications and planning information 121

Connector-pin assignments

External video connector

5 1

10 6

15 11

Table 38. Assignment of external-video connector pins

Pin Connector Pin Connector
1 Red 9 No connection
2 Green 10 Ground
3 Blue 11 No connection
4 No connection 12 Monitor ID1
5 Ground 13 Horizontal sync
6 Red ground 14 Vertical sync
7 Green ground 15 Monitor ID3
8 Blue ground

122 Models 545 and 565 Hardware Service Guide

 Connector-pin assignments

Cash drawer connector (2)

4 1

Table 39. Assignment of cash drawer connector pins

Pin Connector
1 Ground
2 Sensor
3 Open signal
4 +24 V dc

Integrated customer display connector

To access this connector, you must remove the rear cover.
1 4

Table 40. Assignment of integrated customer-display connector pins

Pin Connector
1 +5 V dc at 0.5 A maximum
2 Transmit data
3 Integrated customer display present
4 Ground

Appendix C. System specifications and planning information 123

Connector-pin assignments

Temperature, humidity, and altitude limits

Table 41. Temperature, humidity, altitude limits
Temperature limits Maximum wet bulb
Condition Relative Humidity
(dry bulb) temperature
Operating 5 to 40° C. 8 to 80 % 27° C.
Power Off 0 to 52° C. 5 to 95 % 27° C.
Storage 0 to 60° C. 5 to 100% 29° C.

This product is designed to operate up to 3050 m (10,000 ft.).

124 Models 545 and 565 Hardware Service Guide

Appendix D. Notices
This information was developed for products and services offered in the U.S.A.

IBM may not offer the products, services, or features discussed in this document in
other countries. Consult your local IBM representative for information on the
products and services currently available in your area. Any reference to an IBM
product, program, or service is not intended to state or imply that only that IBM
product, program, or service may be used. Any functionally equivalent product,
program, or service that does not infringe any IBM intellectual property right may be
used instead. However, it is the user’s responsibility to evaluate and verify the
operation of any non-IBM product, program, or service.

IBM may have patents or pending patent applications covering the subject matter in
this document. The furnishing of this document does not give you any license to
these patents. You can send license inquiries, in writing, to:
IBM Director of Licensing
IBM Corporation
North Castle Drive
Armonk, NY 10504-1785
U.S.A.

For license inquiries regarding double-byte (DBCS) information, contact the IBM
Intellectual Property Department in your country or send inquiries, in writing, to:
IBM World Trade Asia Corporation
Licensing
2-31 Roppongi 3-chome, Minato-ku
Tokyo 106, Japan

The following paragraph does not apply to the United Kingdom or any other country
where such provisions are inconsistent with local law: INTERNATIONAL BUSINESS
MACHINES CORPORATION PROVIDES THIS PUBLICATION ″AS IS″ WITHOUT
WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT
NOT LIMITED TO, THE IMPLIED WARRANTIES OF NON-INFRINGEMENT,
MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Some states
do not allow disclaimer of express or implied warranties in certain transactions,
therefore, this statement may not apply to you.

This information could include technical inaccuracies or typographical errors.

Changes are periodically made to the information herein; these changes will be
incorporated in new editions of the publication. IBM may make improvements and/or
changes in the product(s) and/or program(s) described in this publication at any
time without notice.

IBM may use or distribute any of the information you supply in any way it believes
appropriate without incurring any obligation to you.

Any references in this information to non-IBM Web sites are provided for
convenience only and do not in any manner serve as an endorsement of those
Web sites. The materials at those Web sites are not part of the materials for this
IBM product and use of those Web sites is at your own risk.

Information concerning non-IBM products was obtained from the suppliers of those
products, their published announcements or other publicly available sources. IBM

© Copyright IBM Corp. 2006 125

 has not tested those products and cannot confirm the accuracy of performance,
compatibility or any other claims related to non-IBM products. Questions on the
capabilities of non-IBM products should be addressed to the suppliers of those
products.

This information is for planning purposes only. The information herein is subject to
change before the products described become available.

126 Models 545 and 565 Hardware Service Guide

Electronic Emission Notices

Federal Communications Commission (FCC) Statement

This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at
his own expense.

Properly shielded and grounded cables and connectors must be used in order to
meet FCC emission limits. IBM is not responsible for any radio or television
interference caused by using other than recommended cables and connectors or by
unauthorized changes or modifications to this equipment. Unauthorized changes or
modifications could void the user’s authority to operate the equipment.

This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) this device may not cause harmful interference, and (2)
this device must accept any interference received, including interference that may
cause undesired operation.

Industry Canada Class A Emission Compliance Statement

This Class A digital apparatus complies with Canadian ICES-003.

Avis de conformité aux normes d’Industrie Canada

Cet appareil numérique de la classe A est conforme à la norme NMB-003 du
Canada.

European Union (EU) Mark of Conformity Statement

This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to European Standard EN 55022. The
limits for Class A equipment were derived for commercial and industrial
environments to provide reasonable protection against interference with licensed
communication equipment.

Warning: This is a Class A product. In a domestic environment this product may

cause radio interference in which case the user may be required to take adequate
measures.

Properly shielded and grounded cables and connectors must be used in order to
reduce the potential for causing interference to radio and TV communications and
to other electrical or electronic equipment. Such cables and connectors are
available from IBM authorized dealers. IBM cannot accept responsibility for any
interference caused by using other than recommended cables and connectors.

Germany
Zulassungsbescheinigung laut dem Deutschen Gesetz über die
elektromagnetische Verträglichkeit von Geräten (EMVG) vom 30. August 1995
(bzw. der EMC EG Richlinie 89/336).

Appendix D. Notices 127

 Dieses Gerät ist berechtigt in Übereinstimmung mit dem Deutschen EMVG das
EG-Konformitätszeichen - CE - zu führen.

Verantwortlich für die Konformitätserklärung nach Paragraph 5 des EMVG ist die
IBM Deutschland Informationssysteme GmbH, 70548 Stuttgart.

Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:

Das Gerät erfüllt die Schutzanforderungen nach EN 50082–1 und EN 55022 Klasse A.

EN 55022 Klasse A Geräte müssen mit folgendem Warnhinweis versehen werden:

″Warnung: dies ist eine Einrichtung der Klasse A. Diese Einrichtung kann im
Wohnbereich Funkstörungen verursachen; in diesem Fall kann vom Betreiber
verlangt werden, angemessene Maβnahmen durchzuführen und dafür
aufzukommen.″

EN 50082–1 Hinweis:

″Wird dieses Gerät in einer industriellen Umgebung betrieben (wie in EN 50082–2

festgelegt), dann kann es dabei eventuell gestört werden. In solch einem Fall ist der
Abstand bzw. die Abschirmung zu der industriellen Störquelle zu vergröβern.″

Anmerkung:

Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den IBM
Handbüchern angegeben, zu installieren und zu betreiben.

Australia / New Zealand

Attention: This is a Class A product. In a domestic environment this product may
cause radio interference, in which case the user may be required to take adequate
measures.

Japanese power line harmonics compliance statement

Japanese Voluntary Control Council for Interference (VCCI) Statement

This product is a Class A Information Technology Equipment and conforms to the
standards set by the Voluntary Control Council for Interference by Technology
Equipment (VCCI). In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.

128 Models 545 and 565 Hardware Service Guide

Korean Communications Statement
Please note that this device has been approved for business purposes with regard
to electromagnetic interference. If you find this is not suitable for your use, you may
exchange it for a non-business purpose one.

Chinese Class A warning statement

Attention: This is a Class A product. In a domestic environment this product may
cause radio interference in which case the user may be required to take adequate
measures.

Taiwanese Class A Warning Statement

Taiwan contact information

Appendix D. Notices 129

 IBM Taiwan Product Service Contact Info:
IBM Taiwan Corporation
3F, No 7, Song Ren Road, Taipei Taiwan
Telephone: 0800-016-888

Note: Cable ferrites are required to suppress radiated EMI emissions and shall not
be removed.

Taiwan recycle statement

Electrostatic Discharge (ESD)

Attention: ESD damage can occur when there is a difference in charge between
the part, the product, and the service person. No damage will occur if the service
person and the part being installed are at the same charge level.

ESD Damage Prevention

Anytime a service action involves physical contact with logic cards, modules,
back-panel pins, or other ESD sensitive (ESDS) parts, the service person must be
connected to an ESD common ground point on the product through the ESD wrist
strap and cord.

The ESD ground clip can be attached to any frame ground, ground braid, green
wire ground, or the round ground prong on the AC power plug. Coax or connector
outside shells can also be used.

Handling Removed Cards

Logic cards removed from a product should be placed in ESD protective containers.
No other object should be allowed inside the ESD container with the logic card.
Attach tags or reports that must accompany the card to the outside of the container.

Trademarks
The following are trademarks of International Business Machines Corporation in the
United States or other countries, or both:

IBM SurePoint
the IBM logo SurePOS
PS/2 Wake on LAN
SureMark

Microsoft, Windows, Windows NT, and the Windows logo are trademarks of
Microsoft Corporation in the United States, other countries, or both.

Celeron and Intel are trademarks of Intel corporation in the United States, or other
countries.

130 Models 545 and 565 Hardware Service Guide

Java and all Java-based trademarks and logos are trademarks or registered
trademarks of Sun Microsystems, Inc. in the United States, or other countries, or
both.

Other company, product, or service names may be trademarks or service marks of

others.

Appendix D. Notices 131

132 Models 545 and 565 Hardware Service Guide
Appendix E. Safety information
Before you begin to install or service this product, read the following safety
information.

Safety Information-English

DANGER

To avoid a shock hazard, do not connect or disconnect any cables

or perform installation, maintenance, or reconfiguration of this
product during an electrical storm.

DANGER

To avoid shock hazard:

The power cord must be connected to a properly wired and

earthed receptacle.

Any equipment to which this product will be attached must also

be connected to properly wired receptacles.

DANGER

When possible, use one hand to connect or disconnect signal

cables to prevent a possible shock from touching two surfaces
with different electrical potentials.

© Copyright IBM Corp. 2006 133

Safety information

Caution:
A lithium battery can cause a fire, an explosion, or a severe burn. Do not
recharge, disassemble, heat above 100 degree C (212 degree F), solder directly
to the cell, incinerate, or expose the cell contents to water.
Keep away from children.
Replace only with the part number specified for this IBM product. Use of a
different battery may present a risk of fire or explosion. The battery connector is
polarized; do not attempt to reverse the polarity.
Dispose of the battery according to local regulations.

134 Models 545 and 565 Hardware Service Guide

 Safety information

Safety Information-Arabic

Appendix E. Safety information 135

Safety information

136 Models 545 and 565 Hardware Service Guide

 Safety information

Safety Information-Brazilian Portuguese

Appendix E. Safety information 137

Safety information

Cuidado:

Uma bateria de lítio pode causar incêndio, explosão ou queimaduras graves. Não
recarregue, desmonte ou aqueça acima de 100°C (212°F), não utilize solda
diretamente na célula, nem incinere ou exponha o conteúdo da célula à água.

Mantenha longe do alcance de crianças.

Substitua apenas pelo número de peça especificado para este produto IBM. A
utilização de uma bateria diferente representa risco de incêndio ou explosão. O
conector da bateria é polarizado; não tente reverter a polaridade.

Descarte a bateria de acordo com as regulamentações locais.

138 Models 545 and 565 Hardware Service Guide

 Safety information

Safety Information-French

Appendix E. Safety information 139

Safety information

Attention:

Prenez garde aux risques d’incendie, d’explosion ou de brûlures graves liés à

l’utilisation d’une pile au lithium. Ne la rechargez pas et ne la déamontez pas. Ne
l’exposez pas à une température supéeriure à 100 °C, ne la soudez pas, ne la
faites pas brûler et n’en exposez pas le contenu à l’eau.

Gardez la pile hors de portée des enfants.

Si vous la remplacez, commandez une pile de rechange de e. même référence.

Toute autre pile risquerait de prendre feu ou d’exploser. Le connecteur de la pile est
polarisé. N’essayez pas d’inverser la polarité.

140 Models 545 and 565 Hardware Service Guide

 Safety information

Pour le recyclage ou la mise au rebut, reportez-vous à. la ré.glementation en

vigueur.

Appendix E. Safety information 141

Safety information

Safety Information-Hebrew

142 Models 545 and 565 Hardware Service Guide

 Safety information

Appendix E. Safety information 143

Safety information

Safety Information-Korean

144 Models 545 and 565 Hardware Service Guide

 Safety information

Note: In the UK, by law, the telephone Note: In the UK, by law, the power
cable must be connected after the power cord must be disconnected after the
cord. telephone line cable.

Appendix E. Safety information 145

Safety information

146 Models 545 and 565 Hardware Service Guide

 Safety information

Safety Information-Italian

Appendix E. Safety information 147

Safety information

La corrente elettrica di alimentazione del

telefono e dei cavi di comunicazione e'
pericolosa. Per evitare scosse elettriche
collegare e scollegare i cavi, nella sequenza
mostrata in figura, quando si installa, si
trasporta o si tolgono i coperchi di questo
prodotto o delle unita' ad esso collegate.
Non maneggiare i cavi di interconnessione
durante temporali.

Spegnere tutte le unita' (OFF). Spegnere tutte le unita' (OFF).

Collegare i cavi segnali alle unita'. Scollegare il cavo di

alimentazione dalla presa.

Scollegare i cavi segnali

dalle prese.

Collegare i cavi segnali ai

rispettivi connettori.

Scollegare i cavi segnali dalle

unita'.

Collegare il cavo di alimentazione

alla presa.

Accendere tutte le unita' (ON).

Attenzione:

Una batteria al litio può incendiarsi, esplodere o causare ustioni. Non ricaricarla,
non smontarla, non riscaldarla ad una temperatura superiore a 100° C, non
saldarla, non incenerirla, non gettarla in acqua.

Tenere la batteria lontano dalla portata dei bambini.

Sostituirla soltanto con una batteria contrassegnata dal numero parte specifico per
questo prodotto IBM. L’utilizzo di un altro tipo di batteria può determinare rischi di
incendio o di esplosione. Il connettore della batteria è polarizzata; non tentare di
invertire la polarità.

148 Models 545 and 565 Hardware Service Guide

 Safety information

Smaltire la batteria secondo la normativa in vigore (D.Lgs. 22 del 5/2/97) e

successive disposizioni nazionali e disposizioni locali.

Appendix E. Safety information 149

Safety information

Safety Information-Spanish

150 Models 545 and 565 Hardware Service Guide

 Safety information

La corriente eléctrica de la alimentación,

teléfono y cables de comunicación es peligrosa.
Para evitar peligro de descargas cuando instale,
mueva o abra las cubiertas de este producto o
de un disp. conectado, conecte y desconecte
los cables tal como se muestra a continuación.

Apague Todo. Apague Todo.

Primero, conecte todos los cables Primero, quite el cable de la

a los dispositivos. toma de alimentación.

Quite los cables de señal de

los receptáculos.

Conecte los cables de señal

a los receptáculos.

Quite todos los cables de los

dispositivos.

Conecte el cable de alimentación

a la toma de alimentación.

Encienda el dispositivo.

Precaución:

Una batería de litio puede causar un incendio, una explosión o quemaduras graves.
No recargar, desmontar, calentar por encima de los 100 grados C (212 grados F),
soldar directamente a la pila, incinerar o mojar el contenido de la pila.

Manténgala alejada de los niños.

Sustitúyala sólo con el número de pieza que se especifica para este producto IBM.
El uso de una batería distinta puede causar riesgos de incendio o explosión. El
conector de batería está polarizado; no intente invertir la polaridad.

Deseche la batería se acuerdo con la normativa local.

Appendix E. Safety information 151

Safety information

Safety Information-German

VORSICHT
Um gefährliche Spannungen zu vermeiden, dürfen während eines Gewitters
an diesem Gerät keine Kabel angeschlossen oder gelöst werden, ferner keine
Installation, Wartung oder Rekonfiguration durchgeführt werden.

VORSICHT
Aus Sicherheitsgründen
v darf das Netzkabel nur an eine Schutzkontaktsteckdose angeschlossen
werden.
v dürfen für den Anschluβ anderer Geräte an den Drucker auch nur
Schutzkontaktsteckdosen verwendet werden.

VORSICHT
Die Signalkabel nach Möglichkeit mit einer Hand anschlieβen oder lösen, um
gefährliche Körperströme zu vermeiden, die bei Berühren zweier Flächen mit
möglicherweise unterschiedlichen elektrischen Potentialen auftreten können.

152 Models 545 and 565 Hardware Service Guide

 Safety information

Achtung:

Lithiumbatterien sind feuergefährlich, explosiv und können schwere Verbrennungen

verursachen. Batterie nicht wiederaufladen, öffnen oder über 100 Grad Celsius
erhitzen; die Zelle nicht direkt anlöten, verbrennen oder den Inhalt der Zelle mit
Wasser in Berührung bringen.

Batterie nicht in Reichweite von Kindern aufbewahren.

Eine verbrauchte Batterie nur durch eine Batterie mit der für dieses IBM Produkt
spezifizierten Teilenummer ersetzen. Andere Batterien können sich entzünden oder
explodieren. Der Batterieanschluß hat zwei verschiedene Pole; beim Anschließen
die Pole nicht vertauschen.

Batterie gemäß den örtlichen Richtlinien für Sondermüll entsorgen.

Appendix E. Safety information 153

Safety information

Safety Information-Traditional Chinese

154 Models 545 and 565 Hardware Service Guide

 Safety information

Appendix E. Safety information 155

Safety information

156 Models 545 and 565 Hardware Service Guide

Index
Numerics configuring
I/O devices 14
15-pin serial port
power savings 14
connector pin assignments 121
configuring the COM ports 16
4610 SureMark printer, installing 91
connector
15-pin serial pin assignments 121
cash drawer pin assignments 123
A Ethernet pin assignments 121
about this guide xix external video pin assignments 122
accessibility of publications xx headphone pin assignments 119
adapter cable, RJ-45 to 9-pin conversion 28 integrated customer display pin assignments 123
advanced BIOS window 14 keyboard pin assignments 119
altitude limits 124 microphone pin assignments 119
audience xix MSR pin assignments 116
Universal Serial Bus (USB) pin assignments 118
connector pin, assignments 116
B connectors
base plate, removing and replacing 57 speaker pin assignments 116
base-foot countertop mounting connectors, power, and brightness controls 5
mounting the system 67 countertop
batteries integration tray legend 73
disposal xvii integration tray mounting 70
battery, system board 51 mounting the system 65
BIOS countertop and full-size cash drawer 80
flashing procedure 17 countertop mount 67
repairing 18 customer display, integrated 64
update 18
blank, PC card 59
board, planar 49 D
damage from electrostatic discharge 130
default CMOS settings
C clearing 15
cash drawer restoring 15
mounting 75 diagnosing problems
troubleshooting 20 preliminary checklist 19
Cash drawer dimensions 110, 113
connector pin assignments 123 display
cash drawer, countertop and full-size 80 removing and replacing 34
checklist, problem diagnosis 19 display restrictions 7
clearing disposal of equipment xvii
CMOS settings 15 disposing of used products xvii
system password 15 distributed character display and APA display, mounting
clock, real-time 16 to a cash drawer 89
CMOS documentation, related xix
clearing 15 drawer, countertop and full-size cash 80
recovery 23 Driver for Windows, IBM UPOS 7
settings dual video adapter 61
restoring defaults 15
standard features 14
CMOS setup utility E
configuring the COM ports 16 electronic article surveillance device xviii
CMOS Setup Utility electronic emissions 127
Advanced BIOS Features 14 electrostatic discharge (ESD) 130
main window 13 end of life disposal xvii
starting the 13 environmental
compatible products 11 notices xvii
configuration, main window 13 statements xvii

© Copyright IBM Corp. 2006 157

equipment disposal xvii
Ethernet
M
magnetic stripe reader
connector pin assignments 121
connector pin assignments 116
external connectors 116
main window, configuration 13
external video, connector pin assignments 122
management features, system 9
memory keys, supported 17
memory modules
F removing and replacing 55
FCC statement 127 memory modules and industry standards 56
features mercury-added statement xviii
system management 9 microphone
features, optional 4 connector pin assignments 119
field replaceable parts 95 model number location 11
filler panels without a printer, installing 75 Models 545 and 565
flash BIOS update procedure 17 connectors, power, and brightness controls 5
power interruption 18 features and models summary 2
flash, update 18 models and features 2
FRU catalog Models E45 and E65 3
how to use 95 Models P45 and P65 3
full-size cash drawer, countertop and 80 modular servicing and minimum tools 28
mounting
base plate to a countertop 67
H configurations 65
handling static-sensitive devices xviii, 28 Countertop and full-size cash drawe 80
headphone countertop integration tray mounting 70
connector pin assignments 119 non-keyboard-integration tray 70
height 110 mounting the integration tray to a countertop 80
humidity limits 124 mounting the SurePOS 500 65
MSR
removing and replacing 58
I troubleshooting 21
IBM UPOS Drivers for Windows 7 MSR location xviii
information, task 19
installing additional peripheral devices 89
installing filler panels without a printer 75 N
installing the 4610 printer onto the integration tray 85 non-keyboard-integration tray
installing the keyboard-integration tray on a cash mounting the system 70
drawer 83 notices
Integrated customer display environmental xi
connector pin assignments 123 safety xi
integration tray, keyboard, mounting 80 safety translation xi
integration tray, non-keyboard 70 notices, electronic emissions 127

J O
jumper locations, system board 51 opening the I/O tailgate cover 31
operating system and display restrictions 7
operating systems, understanding the supported video
K resolutions and 7
keyboard optional features 4
connector pin assignments 119
troubleshooting 22
keyboard-integration tray mounting 80 P
part numbers
integration tray keyboard, cash drawer and
L countertop 98
Load defaults 15 integration tray non-keyboard, countertop 102
integration turn on— keyboard, cash drawer 104
Models 545 and 565 97
optional peripherals 101

158 Models 545 and 565 Hardware Service Guide

part numbers (continued)
power cords 107
R
real-time clock and CMOS 16
parts catalog 19, 95
rear cover 30
password
recover from flash BIOS update error condition 18
clearing 15
recovery, CMOS 23
setting 15
related publications xix
PC card adapter
remote management 10
removing and replacing 59
removal and replacement procedures
PC health status 15
base plate 57
peripheral devices
cable tie bar 44
4610 SureMark Models TF6 or TF7 printers 91
covers 29
installing 89
front cover 29
pictorial overview of removal and replacements 26
hinge cover 33
pin assignments 116
opening the I/O tailgate cover 31
Ethernet connector 121
rear cover 30
PnP/PCI configurations option 14
top cover 32
power consumption 115
display tablet cable 35
power cords
front bezel and LCD assembly 36
part numbers 107
HDD and HDD bracket 40
power management window 14
HDD cables 43
power ratings, port 115
HDD fan and bracket 42
power requirements 115
hinge assembly 39
power saving
memory modules 55
configuration 14
operator card 38
power supply
optional features
removing and replacing 45
integrated customer display 64
power supply latch arm
MSR 58
opening 46
MSR hole plug 58
power, connectors, and brightness controls 5
PC card blank 59
power, input voltage 115
speaker 62
printer installation, 4610 91
video adapter card 61
printer, installing filler panels without a 75
power supply 45
problem determination 13
power supply latch arm 46
problem diagnosis
processor fan/heatsink assembly 54
preliminary checklist 19
processor module 54
problem diagnosis, start 19
rear connector panel (tailgate) 47
problem symptoms
system board 49
audio is not working 22
system-board battery 51
blank screen 20
tablet, display 34
cash drawer
removing and replacing FRUs 25
display status does not match action 21
processor module 54
does not open 20, 21
replacing FRUs 25
does not open correctly 21
requirements
does not open smoothly 21
power 115
does not stay closed 20
resolutions and operating systems, understanding the
diskette drive does not work 22
supported video 7
keyboard does not work 22
restoring default CMOS settings 15
MSR not reading 21
restrictions, display 7
no power light on operator display tablet 20
RJ-45
no power light on tower unit 20
connector pin assignments 120
operator display backlight dark or dim 21
running diagnostics and troubleshooting 13
running fan 22
touch screen not working 21
processor module 54
product S
disposal xvii safety
products, compatible 11 laser xi
publications xix notice translations xi
related xix notices xi
website xx safety information xi, 131
safety notices 135

Index 159
serial number location 11
serial number, location 14
V
video card
service personnel tools 28
removing and replacing 61
setting
video resolutions and operating systems, understanding
changing, clearing password 15
the supported 7
clearing CMOS 15
restoring default CMOS 15
setup, how to enter 13
size of unit 113 W
skills needed to install, configure, and administer this Wake on Ring 14
product xix web site
speaker 62 IBM Retail Store Solutions 16
speaker, connector pin assignments 116 Web sites xx
specifications weight 110
height 110
weight 110
starting the CMOS Setup Utility 13
static-sensitive devices, handling xviii, 28
summary window, configuration 13
support xx
supported memory keys 17
supported video resolutions and operating systems,
Understanding the 7
system board
jumper locations 51
jumper settings 51
removing and replacing 49
system management features 9

T
tablet, removing and replacing 34
tailgate connector
removing and replacing 47
tailgate cover, opening 31
Taiwan recycle statement 130
tapping twice, touch screen 13
task information 19
temperature limits 124
TF6 and TF7 91
tools, service personnel 28
touch screen
troubleshooting 21
touch screen, tapping twice 13
trademarks 130
troubleshooting 20
preliminary checklist 19

U
understanding the supported video resolutions and
operating systems 7
universal serial bus (USB)
connector pin assignments 118
update flash BIOS 17
UPOS Drivers for Windows, IBM 7
URL, support 16
USB antenna specification 4

160 Models 545 and 565 Hardware Service Guide

Glossary
This glossary includes terms and definitions from: alphanumeric. Pertaining to data consisting of letters,
digits, and usually other characters, such as punctuation
v American National Standard Dictionary for
marks. (T) (A)
Information Systems, ANSI X3.172-1990,
copyright 1990 by the American National analog. (1) Pertaining to data consisting of
Standards Institute (ANSI). Copies may be continuously variable physical quantities. (A) (2)
purchased from the American National Contrast with digital.
Standards Institute, 11 West 42nd Street, New
York, New York 10036. Definitions are identified application. (1) A collection of one or more programs
that work together to accomplish goals for a business.
by the symbol (A) after the definition.
(2) A set of executable files and data files required to
v The Information Technology Vocabulary, perform a desired function, which can consist of multiple
developed by Subcommittee 1, Joint Technical programs running on different workstations.
Committee 1, of the International Organization
for Standardization and the International architecture. A logical structure that encompasses
Electrotechnical Commission (ISO/IEC operating principles including services, functions, and
protocols. See network architecture.
JTC1/SC1). Definitions of published parts of this
vocabulary are identified by the symbol (I) after attach. (1) To connect a device physically. (2) To make
the definition; definitions taken from draft a device a part of a network logically. Compare with
international standards, committee drafts, and connect.
working papers being developed by ISO/IEC
JTC1/SC1 are identified by the symbol (T) after attaching device. Any device that is physically
the definition, indicating that final agreement connected to a network and can communicate over the
network.
has not yet been reached among the
participating National Bodies of SC1.
B
A bit. Either of the digits 0 or 1 when used in the binary
numeration system. Synonymous with binary digit. (T)
active. (1) Able to communicate on the network. A
token-ring network adapter is active if it is able to bus. (1) In a processor, a physical facility on which
transmit and receive on the network (2) Operational. (3) data is transferred to all destinations, but from which
Pertaining to a node or device that is connected or is only addressed destinations may read in accordance
available for connection to another node or device. (4) with appropriate conventions. (2) A network
Currently transmitting or receiving. configuration in which nodes are interconnected through
a bidirectional transmission medium. (3) One or more
adapter. (1) In the point-of-sale terminal, a circuit card
conductors used for transmitting signals or power. (A)
that, with its associated software, enables the terminal
to use a function or feature. (2) In a LAN, within a
communicating device, a circuit card that, with its C
associated software and/or microcode, enables the
device to communicate over the network. cash drawer. An optional I/O device attached to a
point-of-sale terminal. The cash drawer contains a till.
address. (1) In data communication, the The cash drawer will open upon receiving a command.
IEEE-assigned unique code or the unique locally See till.
administered code assigned to each device or
workstation connected to a network. (2) A character or CPU. The central processing unit of a computer.
group of characters that identifies a register, a particular
part of storage, or some other data source or circuit. (1) A logic device. (2) One or more conductors
destination. (A) (3) To refer to a device or an item of through which an electric current can flow.
data by its address. (I) (A) (4) The location in the
storage of a computer where data is stored. cluster. (1) A station that consists of a control unit (a
cluster controller) and the terminals attached to it. (2) A
addressing. (1) The assignment of addresses to the group of APPN nodes that have the same network ID
instructions of a program. (2) In data communication, and the same topology database. A cluster is a subset
the way in which a station selects the station to which it of a NETID subnetwork. (3) In high-availability cluster
is to send data. multiprocessing (HACMP), a set of iindependent
systems (called nodes) that are organized into a

© Copyright IBM Corp. 2006 161

network for the purpose of sharing resources and performs input, processing, storage, output, and control
communicating with each other. functions to accomplish a sequence of operations on
data. (A) (I)
collision. (1) An unwanted condition that results from
concurrent transmissions on a channel. (T) (2) When a data set. Logically related records treated as a single
frame from a transmitting adapter encounters any other unit. See also file.
signal in its path (frame, noise, or another type of
signal), the adapter stops transmitting and a collision is DBCS. See double-byte character set.
registered.
device. (1) A mechanical, electrical, or electronic
command. (1) A request for performance of an contrivance with a specific purpose. (2) An input/output
operation or execution of a program. (2) A character unit such as a terminal, display, or printer. See also
string from a source external to a system that attaching device.
represents a request for system action.
diagnostic diskette. A diskette containing diagnostic
component. (1) Any part of a network other than an modules or tests used by computer users and service
attaching device, such as an IBM 8228 Multistation personnel to diagnose hardware problems.
Access Unit. (2) Hardware or software that is part of a
functional unit. diagnostics. Modules or tests used by computer users
and service personnel to diagnose hardware problems.
configuration. (1) The devices and programs that
make up a system, subsystem, or network. (A) See also digital. (1) Pertaining to data in the form of digits. (A)
system configuration. (2) In the IBM StorePlace Contrast with analog. (2) Pertaining to data consisting of
Distributed Data Services for OS/2, program options numerical values or discrete units.
that are initially set at installation, and that can be
DIP switch. A two-position switch on a circuit board
changed later. Changing these options requires an IPL.
that is preset to control certain functions. The user can
These changes must be performed by a programmer or
change the position of a DIP switch to satisfy special
store operations personnel. These options are used to
requirements.
tune the product’s use of the operating system and
machine resources. disk. A round, flat, data medium that is rotated in order
to read or write data. (T) See also diskette, hard-disk
connect. In a LAN, to physically join a cable from a
drive.
station to an access unit or network connection point.
Contrast with attach. disk operating system (DOS). A computer operating
system that can perform only one task at a time.
controller. A unit that controls input/output operations
for one or more devices. diskette. A thin, flexible magnetic disk permanently
enclosed in a protective jacket. A diskette is used to
cursor. A movable point of light (or a short line) that
store information for processing.
indicates where the next character is to be entered on
the display screen. diskette drive. The mechanism used to seek, read,
and write data on diskettes.
D display. (1) A visual presentation of data. (2) A device
that presents visual information to the point-of-sale
data. (1) A representation of facts, concepts, or
terminal operator and to the customer.
instructions in a formalized manner suitable for
communication, interpretation, or processing by human distributed. Physically separate but connected by
or automatic means. (I) (A) (2) Any representations such cables.
as characters or analog quantities to which meaning is
or might be assigned. (A) DOS. See disk operating system.

data file. A collection of related data records organized double-byte character set (DBCS). A set of
in a specific manner; for example, a payroll file (one characters in which each character is represented by 2
record for each employee, showing such information as bytes. Languages such as Japanese, Chinese, and
rate of pay and deductions) or an inventory file (one Korean, which contain more symbols than can be
record for each inventory item, showing such represented by 256 code points, require double-byte
information as cost, selling price, and number in stock.) character sets. Because each character requires 2
See also data set, file. bytes, the typing, display, and printing of DBCS
characters requires hardware and programs that support
data processing system. A system, including DBCS. Contrast with single-byte character set.
computer systems and associated personnel, that
DRAM. Dynamic RAM. See RAM.

162 Models 545 and 565 Hardware Service Guide

driver. A software component that controls a device. (IBM PC Network), all frames including the token frame
contain a preamble, start delimiter, control address,
dump. (1) To record, at a particular instant, the optional data and checking characters, end delimiter,
contents of all or part of one storage device in another and are followed by a minimum silence period. (2) A
storage device. Dumping is usually for the purpose of housing for machine elements. (3) In synchronous data
debugging. (T) (2) Data that has been dumped. (T) link control (SDLC), the vehicle for every command,
every response, and all information that is transmitted
DVD-ROM. Digital-video-disk read-only memory. using SDLC procedures. Each frame begins and ends
with a flag.
E function. (1) A specific purpose of an entity, or its
error message. A message that is issued because an characteristic action. (A) (2) In data communications, a
error has been detected. machine action such as a carriage return or line feed.
(A)

F G
FCC. See Federal Communications Commission.
Ghz. The abbreviation for gigahertz. One GHz
feature. A part of an IBM product that may be ordered represents 1 billion cycles per second. The speed of
separately by the customer. microprocessors, called the clock speed, often is
measured in gigahertz.
Federal Communications Commission (FCC). A
board of commissioners appointed by the President
under the Communications Act of 1934, having the
H
power to regulate all interstate and foreign
hard-disk drive. In a personal computer system unit,
communications by wire and radio originating in the
a disk storage device that reads and writes on rigid
United States.
magnetic disks. It is faster and has a larger storage
field. On a data medium or a storage medium, a capacity than a diskette and is permanently installed.
specified area used for a particular category of data; for Synonymous with fixed disk.
example, a group of character positions used to enter or
HID. See human interface devices.
display wage rates on a panel. (T)
hot pluggable. Refers to a hardware component that
file. A named set of records stored or processed as a
can be installed or removed without disturbing the
unit. (T) For example, an invoice may form a record and
operation of any other resource that is not connected to,
the complete set of such records may form a file. See
or dependent on, this component.
also data set.
human interface devices (HID). Devices which allow
.
humans to interact and communicate with a computer.
FSB. Another name for the system bus. The system Examples are a keyboard or a mouse.
bus is also called the frontside bus, memory bus, local
hot plugging. Process of installing connections to the
bus, or host bus.
serial bus while the system is running and without
flash memory. A data-storage device that is powering down.
programmable, erasable, and does not require
hot unplugging. Process of removing connections
continuous power. The chief benefit of flash memory
from the serial bus while the system is running and
over other programmable and erasable data storage
without powering down.
devices is that it can be reprogrammed without being
removed from the circuit board. hypertext. (1) A method of presenting text in discrete
units, or nodes, that are connected by links for
formatted diskette. A diskette on which track and
navigation. (2) Text designed to be read or accessed in
sector control information has been written and that can
a nonlinear manner using nodes that are connected by
be used by the computer to store data. Note: A diskette
links for navigation.
must be formatted before it can receive data.

frame . (1) The unit of transmission in some LANs, I

including the IBM Token-Ring Network and the IBM PC
Network. It includes delimiters, control characters, I/O. See input/output.
information, and checking characters. On a token-ring
network, a frame is created from a token when the
token has data appended to it. On a token-bus network

Glossary 163
I/O device. A device in a data processing system by line. On a terminal, one or more characters entered
means of which data can be entered into the system, before a return to the first printing or display position.
received from the system, or both. (I) (A)
link. (1) The logical connection between nodes
IBM Disk Operating System (DOS) . A disk operating including the end-to-end link control procedures. (2) The
system based on MS-DOS that operates with all combination of physical media, protocols, and
IBM-compatible personal computers. programming that connects devices on a network. (3) In
computer programming, the part of a program, in some
IEEE. Institute of Electrical and Electronics Engineers. cases a single instruction or an address, that passes
control and parameters between separate portions of
input/output (I/O). (1) Pertaining to a device whose the computer program. (4) To interconnect items of data
parts can perform an input process and an output or portions of one or more computer programs. (5) In
process at the same time. (I) (2) Pertaining to a SNA, the combination of the link connection and link
functional unit or channel involved in an input process, stations joining network nodes. See also link
output process, or both, concurrently or not, and to the connection. Note: A link connection is the physical
data involved in such a process. medium of transmission; for example, a telephone wire
or a microwave beam. A link includes the physical
integrated. Arranged together as one unit.
medium of transmission, the protocol, and associated
interference. (1) The prevention of clear reception of devices and programming; it is both logical and
broadcast signals. (2) The distorted portion of a physical.
received signal.
link connection. (1) All physical components and
interrupt. (1) A suspension of a process, such as protocol machines that lie between the communicating
execution of a computer program, caused by an link stations of a link. The link connection may include a
external event and performed in such a way that the switched or leased physical data circuit, a LAN, or an
process can be resumed. (A) (2) To stop a process in X.25 virtual circuit. (2) In SNA, the physical equipment
such a way that it can be resumed. (3) A means of providing two-way communication and error correction
passing processing control from one software or and detection between one link station and one or more
microcode module or routine to another, or of requesting other link stations. (3) In the IBM Store System, the
a particular software, microcode, or hardware function. logical link providing two-way communication of data
from one network node to one or more other network
nodes.
J
load. In computer programming, to enter data into
jabber. Transmission by a data station beyond the memory or working registers.
time interval allowed by the protocol. (T)
local area network (LAN). A computer network
located on a user’s premises within a limited
K geographical area. Note: Communication within a LAN
is not subject to external regulations; however,
K. When referring to storage capacity, a symbol that communication across the LAN boundary may be
represents two to the tenth power, or 1024. subject to some form of regulation.
keyboard. A group of numeric keys, alphabetic keys, logon. The procedure for starting up a point-of-sale
special character keys, or function keys used for terminal or store controller for normal sales operations
entering information into the terminal and into the by sequentially entering the correct security number and
system. transaction number. Synonymous with sign-on.

L M
LAN. See local area network. magnetic ink character reader (MICR). An input unit
that reads characters by magnetic ink character
LAN adapter. The circuit card within a communicating
recognition. (A)
device (such as a personal computer) that, together with
its associated software, enables the device to be magnetic ink character recognition. (1) MICR.
attached to a LAN. Character recognition of magnetic ink characters. (T) (2)
The identification of characters through the use of
LED. Light-emitting diode.
magnetic ink.
light-emitting diode (LED). A semiconductor chip that
MB. See megabyte.
gives off visible or infared light when activated.
Mbps. One million bits per second.

164 Models 545 and 565 Hardware Service Guide

megabyte (MB) . A unit of measure for data. 1 Operating System/2® (OS/2®). A set of programs that
megabyte = 1 048 576 bytes. control the operation of high-speed large-memory IBM
Personal Computers providing multitasking. Contrast
memory. Program-addressable storage from which with Disk Operating System (DOS).
instructions and other data can be loaded directly into
registers for subsequent execution or processing. operator. A person who operates a machine.

memory key. A USB removable storage device. operator message. A message from the operating
system or a program telling the operator to perform a
message. (1) An arbitrary amount of information specific function or informing the operator of a specific
whose beginning and end are defined or implied. (2) A condition within the system, such as an error condition.
group of characters and control bit sequences
transferred as an entity. (3) In telecommunication, a option. (1) A specification in a statement, a selection
combination of characters and symbols transmitted from from a menu, or a setting of a switch, that can be used
one point to another. (4) A logical partition of the user to influence the execution of a program. (2) A hardware
device’s data stream to and from the adapter. See also or software function that can be selected or enabled as
error message, operator message. part of a configuration process. (3) A piece of hardware
(such as a network adapter) that can be installed in a
MICR. See magnetic ink character reader and device to modify or enhance device function.
magnetic ink character recognition.
OS. Operating system.
module. A program unit that is discrete and identifiable
with respect to compiling, combining with other units, OS/2. Operating System/2.
and load; for example, the input to, or output from, an
assembler, compiler, linkage editor, or executive routine.
P
N page. The information displayed at the same time on
the screen of a display device.
network. (1) A configuration of data processing
devices and software connected for information panel. (1) A thin flat sheet, usually (a) of pressed
interchange. (2) An arrangement of nodes and metal and carrying controls and indicators, (b) of glass,
connecting branches. Connections are made between or (c) of plastic. (2) A formatted display of information
data stations. that appears on a display screen.

network architecture. The logical structure and parallel port. A port that transmits the bits of a byte in
operating principles of a computer network. Note: The parallel along the lines of the bus, one byte at a time, to
operating principles of a network include those of an I/O device. On a personal computer, it is used to
services, functions, and protocols. connect a device that uses a parallel interface, such as
a dot matrix printer, to the computer. Contrast with serial
noise. (1) A disturbance that affects a signal and that port.
can distort the information carried by the signal. (2)
Random variations of one or more characteristics of any PC. See personal computer.
entity, such as voltage, current, or data. (3) Loosely, any
disturbance tending to interfere with normal operation of personal computer (PC). A desk-top, free-standing, or
a device or system. portable microcomputer that usually consists of a
system unit, a display, a keyboard, one or more diskette
nonvolatile random access memory (NVRAM) . drives, internal fixed-disk storage, and an optional
Random access memory that retains its contents after printer. PCs are designed primarily to give independent
electrical power is shut off. Contrast with volatile computing power to a single user and are inexpensively
memory. priced for purchase by individuals or small businesses.
Examples include the various models of the IBM
NVRAM. See nonvolatile random access memory. Personal Computers.

plug. (1) A connector for attaching wires from a device

O to a cable, such as a store loop. A plug is inserted into
a receptacle or plug. (2) To insert a connector into a
operating system. Software that controls the receptacle or socket.
execution of programs and that may provide services
such as resource allocation, scheduling, input/output Plug and Play (PnP). Pertaining to the capability of a
control, and data management. Although operating hardware or software component to be installed on a
systems are predominantly software, partial hardware system with minimal effort and to be available for use
implementations are possible. (T) immediately thereafter.

Glossary 165
PnP. See Plug and Play. record. A collection of related items of data, treated as
a unit; for example, in stock control, each invoice could
point-of-sale (POS). A method of providing constitute one record. A complete set of such records
information to support sales and of collecting the may form a file.
resulting sales information from retail devices located in
stores. repeater. A device that amplifies or regenerates data
signals in order to extend the range of transmission
port. (1) An access point for data entry or exit. (2) A between devices in a network.
connector on a device to which cables for other devices
such as display stations and printers are attached.
Synonymous with socket. S
POS. See point-of-sale. SBCS. See single-byte character set.

POST . Power-on self-test. scanner. A device that examines the bar code on
merchandise tickets, credit cards, and employee badges
power-on self-test (POST) . A series of diagnostic and generates analog or digital signals corresponding to
tests that are run automatically each time the the bar code.
computer’s power is switched on.
serial port. On personal computers, a port used to
problem determination. The process of determining attach devices such as display devices, letter-quality
the source of a problem; for example, a program printers, modems, plotters, and pointing devices such as
component, machine failure, telecommunication light pens and mice; it transmits data one bit at a time.
facilities, user or contractor-installed programs or Contrast with parallel port.
equipment, environmental failure such as a power loss,
or user error. signal. A variation of a physical attribute, used to
convey data. (A)
procedure. (1) A set of related control statements that
cause one or more programs to be performed. (2) A set single-byte character set (SBCS). Single-byte
of instructions that gives a service representative a character set. A character set in which each character is
step-by-step procedure for tracing a symptom to the represented by a one-byte code. Contrast with
cause of failure. double-byte character set.

processor. In a computer, a functional unit that socket. (1) An opening that holds something. (2)
interprets and executes instructions. (A) (I) Synonym for port.

protocol. (1) A set of semantic and syntactic rules that source. The origin of any data involved in a data
determine the behavior of functional units in achieving transfer.
communication. (I) (2) A specification for the format and
relative timing of information exchanged between subsystem. A secondary or subordinate system,
communicating parties. usually capable of operating independently of, or
asynchronously with, a controlling system. (T)

R switch. (1) A device for making and breaking electrical

connections, for making a selection, or for requesting a
RAM. See random access memory. function or operation. (2) On an adapter, a mechanism
used to select a value for, enable, or disable a
random access memory (RAM). A computer’s or configurable option or feature.
adapter’s volatile memory, which can be accessed
nonsequentially. system. (1) In data processing, a collection of people,
machines, and methods organized to accomplish a set
read. To acquire or to interpret data from a storage of specific functions. (I) (A) See also data processing
device, from a data medium, or from another source. (I) system, operating system, and system unit. (2) In the
(A) IBM StorePlace Distributed Data Services for OS/2, a
group of nodes for which files are managed.
real-time. (1) Pertaining to the actual time during
which a physical process occurs. (2) Pertaining to data system board. In a system unit, the main circuit board
collected concurrently with physical events, so that the that supports a variety of basic system devices, such as
results of the collection operation may be used to a keyboard or a mouse, and provides other basic
influence the sequence of events. system functions.
receive. To obtain and store information transmitted system bus. The unit that connects the CPU to the
from a device. main memory on the motherboard.

166 Models 545 and 565 Hardware Service Guide

system configuration. A process that specifies the vital product data (VPD). Information about the
devices and programs that form a particular data computer, such as machine type and model or serial
processing system. number, stored in the BIOS.

system unit. (1) A part of a computer that contains the volatile memory. Memory that loses its contents when
processing unit and may contain devices such as disk power is turned off.
and diskette drives. (2) In an IBM Personal Computer,
the unit that contains the processor circuitry, read-only VPD. See vital product data.
memory (ROM), random access memory (RAM), and
the I/O channel. It may have one or more disk or
diskette drives. (3) In an IBM Store System terminal, the
part of the terminal that contains the processing unit,
ROM, RAM, disk and diskette drives, and the I/O
channel.

T
terminal. In data communication, a device, usually
equipped with a keyboard and a display, that is capable
of sending and receiving information.

till. A tray in the cash drawer of the point-of-sale

terminal, used to keep the different denominations of
bills and coins separated and easily accessible.

transmit. To send information from one place for

reception elsewhere. (A)

twisted pair. A transmission medium that consists of

two insulated electrical conductors twisted together. (A)

typematic. The ability of a key on a keyboard to

repeatedly type a character as long as it is held down.

U
Universal Serial Bus (USB). A serial interface
standard for telephony and multimedia connections to
personal computers.

Universal Serial Bus (USB), powered. A

powered-USB connector provides additional power from
the host system. A powered-USB receptacle consists of
two connectors stacked vertically inside the common
housing. The upper connector contains four contacts
that are used for powering the attached device.

unshielded twisted pair (UTP). One or more twisted

pairs of copper wire in the unshielded voice-grade cable
commonly used to connect a telephone to its wall jack.

user. (1) A category of identification defined for file

access protection. (2) A person using a program or
system.

USB. See Universal Serial Bus.

V
version . A separately licensed program that usually
has significant new code or new function.

Glossary 167
168 Models 545 and 565 Hardware Service Guide
Part number index
Part Asm– Part Asm–
Number Index Page Number Index Page
12X1000 1–2 97 42V3948 1–20 97
12X1001 1–2 97 42V3949 1–20 97
12X1009 1–22 97 42V3950 1–14 97
12X1036 1–6 97 42V3951 1– 97
12X1110 1–23 97 42V3952 1– 97
12X1129 4–6 103 42V3953 1–15 97
12X1129 5–6 105 42V3956 1– 97
14R0157 2– 99 42V3957 1– 97
20P0308 5–5 105 42V3958 3–3 101
41D0171 1– 97 42V3959 3–4 101
41D0210 5–1 105 42V3960 3–1 101
41D0211 4–2 103 42V3961 3–1 101
41D0211 5–2 105 42V3964 2–2 99
41D0212 4– 103 42V3965 2–3 99
41D0214 2–1 99 42V3966 4–3 103
41D0216 2– 99 42V3966 5–3 105
41D0261 4–1 103 42V3967 4–4 103
41D9746 1– 97 42V3967 5–4 105
41P0212 5– 105 42V3969 1– 97
42A3641 1– 97 42V3980 1– 97
42N5755 1–17 97 45P6222 1– 97
42N5755 3–2 101 47P9273 2–4 99
42V3682 1–27 97
42V3886 1–1 97
42V3887 1–1 97
42V3889 1–3 97
42V3890 1–3 97
42V3892 1–6 97
42V3893 1–5 97
42V3894 1–5 97
42V3897 1–4 97
42V3922 1–10 97
42V3924 1–7 97
42V3925 1–9 97
42V3927 1–11 97
42V3928 1–11 97
42V3930 1–16 97
42V3931 1–13 97
42V3932 1–25 97
42V3933 1–26 97
42V3935 1–24 97
42V3936 1–19 97
42V3937 1–8 97
42V3938 1–21 97
42V3939 1– 97
42V3940 1–28 97
42V3943 1–12 97
42V3944 1– 97
42V3945 1–18 97
42V3947 1– 97

© Copyright IBM Corp. 2006 169

170 Models 545 and 565 Hardware Service Guide
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