Helios Panel I/O Board User Manual
Contents
1. HELIOS PANEL I O BOARD User Manual Revision A 01 March 2015 5 9 11 Initial Release 3 3 15 Minor update to Power section Copyright 2015 FOR TECHNICAL SUPPORT Diamond Systems Corporation PLEASE CONTACT 555 Ellis Street Mountain View CA 94043 USA support diamondsystems com Tel 1 650 810 2500 Fax 1 650 810 2525 www diamondsystems com Q oiamonn SYSTEMS CONTENTS Important Safe Handling Information cccccsssessseeeeeeeeeeeeenneeeeeeeeeeeessseeeeeeseoooesssseeeeeseeooesssseeeseseoooensseeeeeessenes 3 e DISCO TIOIN WE 4 2 BOCK DIOTAN eei E AE EE a EE EE E 4 S Mechanical ANG EE 5 4 leie iv RR E e d N E 6 Al OBOTO SCO ME 6 4 2 Expansion O Section scccccccscccsciescctesesdcecssecdsadedesdcecsnecncnsssaneceeccnsdsavesansceateactsnvaansaeecccecddetsaesd ectecassazeacededstousese 6 A PONG SOCON EE 6 5 SBC I O Section ene TE 7 e ENEMO EE 7 52 WU OW EE 7 99 PS2 K ypboard MOUSE eet n a AE Ra A E E EAEE 7 94 VOA CONNECCION resinen aa E a E A A AE E 7 Do EE Eegeregie eege 8 6 6 USB EC Gnd USB 2 3 COMMCCIONS eege e ed eegen 8 MOV E 8 5 8 Data ACQUISITION V O CONMECIOL a cccste2 ciscc2esqcnsen2cesscucsneepadauendssedsansbeediaueGtnssaauRedetecediadecodttaabacdpeedeceatahedecgneedscenss 9 5 9 Miscelaneous e TE 9 6 SBC I O Section Top ET TEE 10 Gell OUT e EE 10 O gt EE 10 SE NEE E 10 64A EE eeben 10 6 5 PS 2 Keyboard and Mouse 10 06 WD AV ee E INO ivrnsiasecamamonenncmncreseenanteamcenanistsnctwuneencun2. 1 DESCRIPTION DIAMOND SYSTEMS The Helios panel I O board plugs directly onto the Helios PC 104 single board computer and provides industry type I O connectors for all I O features on the board The panel I O board mounts in the Pandora enclosure to provide a cable free mounting system for Helios Key feature highlights include Plugs onto the Helios SBC and provides all I O without cables e 2 BLOCK DIAGRAM 50 Pin Connector 20 Pin Connector Helios CPU 10 100 Ethernet COM1 COM4 VGA PS 2 Keyboard Mouse USBO USB3 Miscellaneous 16 Digital I O SPI Data Acquisition PC 104 Bus MiniDIN6 2 USB A 4 Speaker Reset Switch DB25F 50 Pin Connector Power Supply Connectors Connections for front panel switch DC DC Power Supply separate device Helios Panel I O Board User Manual Rev A 01 Input Power Connector Provides additional front panel I O for 2 additional PC 104 boards Mounts in Pandora enclosure Provides connection for power switch Provides power paths for 5V and variable voltage input Expansion I O Section CPU I O Section Power Section www diamondsystems com Page 4 iamono SYSTEMS 3 MECHANICAL DRAWING A mechanical drawing of the Helios panel I O board connector layout is provided below The drawing shows the top
3. side of the panel I O board with the relative connector locations All UO connectors are located on the board so that there is sufficient room to install all connectors without interference with any other connector or mounting hole o EEE MISC Expansion COM gt 1 zmo leng Ort j SUR UK i d Do e D ef o Zeg lee S 4 Speaker 2 ze eej gt cee gt ee 99 ee gt ege lee ee ww ee oo ee ae oe TT ee A UE oo ee 99 ee USB1 ee lee e mmm es ee lee ee eene o ee lee eo ee UE 5 105 ee S kk AE eg E k L ee lee eez gt ee 0e R ee E ee oe 8 eos Sooo oo oo 0 kA 5 3 ege lt USB3 COM4 ee 99 ee kb AE e Op oe oo 8 ee eo oe e ee TT ee ee UL en PC 104 C 2007 DIAMOND SYSTEMS lower left hole 0 395 0 965 0 825 o a radius 063 or less a 0 965 1 405 3 645 4 965 5 360 FABRICATION DRAWING Helios Panel I O Board Top Side Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 5 iamonp SYSTEMS 4 FUNCTIONAL DESCRIPTION The panel I O board contains three major sections SBC I O section Expansion I O section and Power section 4 1 SBCI O Section The SBC I O section brings out all the SBC I O to the front panel connectors The top side of the panel I O board has industry standard I O connectors and the bottom side provides dual row 2mm pin sockets to mate with the correspondi
4. C supply connector Vin Input to DC DC Vin switch bypass jumper R15 5 Output from DC DC 5V switch connection J25 12 input option R150 PC 104 is a trademark of the PC 104 Embedded Consortium All other trademarks are the property of their respective owners Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 13
5. Page 11 piamono SYSTEMS 7 EXPANSION I O SECTION These connectors are on the bottom side of the panel I O board outside the PC 104 outline They do not connect to the Helios SBC They are used for other internal connections and functions Both connectors are 0 1 pitch male pin headers 7 1 Serial Port Expansion The serial port expansion connector is a 2x10 pin 0 1 pitch male pin header Its signals are brought out to two DB9 male connectors for serial ports 5 6 on the top side of the panel I O board The signal routing is described below Panel Panel Signal Expansion Signal Panel _ Connector Pm Name Connector Name Pin COM5 1 DCD 5 2 RXD 5 3 TXD5 _ 5 6 4 DTR5 7 5 7 2 General Purpose Expansion The general purpose I O expansion connector is a 2x25 pin 0 1 pitch male pin header The signals have a 1 to 1 correspondence with the 50 pin expansion I O connector on the top side of the panel I O board Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 12 iamono SYSTEMS 8 POWER SECTION The power section provides the means to bring power to the system The schematic below indicates the power routing between the input power connector and the Helios SBC through the panel I O board Power may be provided in several methods 1 5V in from the input power connector directly to the panel I O board using either the front panel switch or a direct connection and then the Helios SBC through
6. artnescadtiamana EE EEA EEE EA EEEE EE E EEES 10 67 Ond E 11 S Dona e E E O E E O E A 11 6 9 Expansion I O Connector Evtemalt 11 e EXPANSION O SOC OM E 12 7 1 Serial Port EXPANSION 2 0 cece ccccccsseeececceeeeseeeeceeeeeeeeecaeeeeceeecsaaseeeeeceaaeeeeessseaeeeesseeeaeeeeesseaaeeeessaeaeeeesseseneeeeeeaas 12 7 2 General Purpose Evpansion eeren 12 O Oe Te E 13 Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 2 piamono SYSTEMS IMPORTANT SAFE HANDLING INFORMATION WARNING ESD Sensitive Electronic Equipment Observe ESD safe handling procedures when working with this product Always use this product in a properly grounded work area and wear appropriate ESD preventive clothing and or accessories Always store this product in ESD protective packaging when not in use Safe Handling Precautions Aurora contains numerous UO connectors that connect to sensitive electronic components This creates many opportunities for accidental damage during handling installation and connection to other equipment The list here describes common causes of failure found on boards returned to Diamond Systems for repair This information is provided as a source of advice to help you prevent damaging your Diamond or any vendor s embedded computer boards ESD damage This type of damage is almost impossible to detect because there is no visual sign of failure or damage The symptom is that the board simply stops working b
7. e serial port connectors are 6 vertical DB9 male connectors They have 4 40 thread inserts and hex screwlocks Ports 1 4 signals come from the 40 pin SBC serial port connector and use the pinout shown below Ports 5 6 signals come from the 20 pin expansion connector and their pinout is given in section 7 1 Panel Panel Signal Serial Port Signal Panel Connector Pm Name Connector Name Pin COM1 1 2 3 4 one eee AND COM2 1 2 3 4 oe eee eee eee AND COM 1 2 3 4 SE COM4 1 2 3 4 5 6 8 Digital UO The digital I O connector is a vertical DB25 female connector with the following pinout It has 4 40 thread inserts and hex screwlocks The signals come from the Helios SBC mating digital I O connector DB25 Pin Signal Name DIO LCAO DIO LCA2 DIO LCA4 DIO LCA6 DIO LCBO DIO LCB2 DIO LCB4 DIO LCB6 CPU Connector 6 9 Expansion I O Connector External The external expansion I O connector is a vertical 50 pin connector with long ejector latches for a mating ribbon cable connector with strain relief The signals come from the general purpose expansion I O connector on the bottom side of the panel I O board and have a 1 to 1 correspondence with that connector s pinout Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Signal Name DIO LCA1 DIO LCA3 DIO LCAS DIO LCA7 DIO LCB1 DIO LCB3 DIO LCB5 DIO LCB7 GND GND NC NC NC DB25 Pin 14 15 16 17 18 19 20 21 22 23 24 25
8. ecause some component becomes defective Usually the failure can be identified and the chip can be replaced To prevent ESD damage always follow proper ESD prevention practices when handling computer boards Damage during handling or storage On some boards we have noticed physical damage from mishandling A common observation is that a screwdriver slipped while installing the board causing a gouge in the PCB surface and cutting signal traces or damaging components Another common observation is damaged board corners indicating the board was dropped This may or may not cause damage to the circuitry depending on what is near the corner Most of our boards are designed with at least 25 mils clearance between the board edge and any component pad and ground power planes are at least 20 mils from the edge to avoid possible shorting from this type of damage However these design rules are not sufficient to prevent damage in all situations A third cause of failure is when a metal screwdriver tip slips or a screw drops onto the board while it is powered on causing a short between a power pin and a signal pin on a component This can cause overvoltage power supply problems described below To avoid this type of failure only perform assembly operations when the system is powered off Sometimes boards are stored in racks with slots that grip the edge of the board This is a common practice for board manufacturers However our boards are general
9. ector provides the standard PS 2 keyboard and mouse signals For a standard configuration a 2x4 connector may be installed in positions 1 8 for compatibility with the existing DSC cable For a latching configuration the 2x5 connector is installed 5V KB Data KB Clk Ground NC 5 4 VGA Connector This connector provides a connection for VGA monitors Note that while the DDC serial detection pins are present there is no 5V supply provided nor are the old Monitor ID pins used RED Ground GREEN NC BLUE Ground HSYNC DDC Data VSYNC DDC Clock Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 7 DIAMOND SYSTEMS 5 5 Serial Ports This connector provides access to the four serial ports from the Vortex CPU chip Ports 1 and 2 may be jumper configured for RS 232 RS 422 or RS 485 protocols while ports 3 and 4 are fixed RS 232 only RS 232 Configuration RS 422 Configuration RS 485 configuration 5 6 USB 0 1 and USB 2 3 Connectors These connectors provide access to the 4 USB 2 0 ports The shield pin is tied to system ground The Key positions are missing to match the key position in the cable to prevent misconnection NC Shield Ground USB1 Pwr USBO Pwr USB1 Data USBO Data USB1 Data USBO Data USB1 Pwr USBO Pwr NC Shield Ground USB3 Pwr USB2 Pwr USB3 Data USB2 Data USB3 Data USB2 Data USB3 Pwr USB2 Pwr 5 7 Digital I O This connector provides 16 digital I O signals fr
10. ly very dense and if the board has components very close to the board edge they can be damaged or even knocked off the board when the board tilts back in the rack Diamond recommends that all our boards be stored only in individual ESD safe packaging If multiple boards are stored together they should be contained in bins with dividers between boards Do not pile boards on top of each other or cram too many boards into a small location This can cause damage to connector pins or fragile components Power supply wired backwards Our power supplies and boards are not designed to withstand a reverse power supply connection This will destroy each IC that is connected to the power supply In this case the board will most likely will be unrepairable and must be replaced A chip destroyed by reverse power or by excessive power will often have a visible hole on the top or show some deformation on the top surface due to vaporization inside the package Check twice before applying power Bent connector pins This type of problem is often only a cosmetic issue and is easily fixed by bending the pins back to their proper shape one at a time with needle nose pliers This situation can occur when pulling a ribbon cable off of a pin header Note If the pins are bent too severely bending them back can cause them to weaken unacceptably or even break and the connector must be replaced Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 3
11. ng 2mm pin headers on the Helios SBC 4 2 Expansion I O Section The Expansion I O section contains additional connectors for bringing out the I O from PC 104 modules installed below the Helios SBC within the enclosure The first expansion connector provides I O for a generic PC 104 I O board It includes a 50 pin 2x25 1 pitch pin header for mating with a standard ribbon cable that connects to the I O connector of a PC 104 board This pin header is on the bottom right side of the panel I O board in a spot convenient for mating with the standard PC 104 board I O connector location On the top side a latching 50 pin connector is provided for external access to this I O The second expansion connector provides I O for a Diamond Emerald EMM XT or EMM 4M XT serial port board It provides a 2x10 1 pitch pin header on the bottom left side for connection to the EMM board and 2 DB9M connectors on the top side for external access 4 3 Power Section The Power section provides two paths for input power coming from either a 5VDC source or a variable input voltage source The 5V source is routed through a 1x2 1 pitch friction lock connector to a front panel switch and then to a pin socket on the bottom side that mates with the Helios SBC The switch connector can be bypassed with a jumper if desired The variable input voltage source is routed through another 1x2 1 pitch friction lock connector to a front panel switch and then to a separa
12. om the Helios SBC It connects to a DB25F connector on the front panel It is a 2x10 1 pitch female pin socket connector DIO LCAO DIO LCA1 DIO LCA2 DIO LCA3 DIO LCA4 DIO LCA5 DIO LCA6 DIO LCA7 DIO LCBO DIO LCB1 DIO LCB2 DIO LCB3 DIO LCB4 DIO LCB5 DIO LCB6 DIO LCB7 5V GND NC GND Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 8 5 8 Data Acquisition I O Connector piamonp SYSTEMS This connector provides data acquisition signals from the Helios SBC board if the model supports data acquisition It connects to a 50 pin male pin header on the front panel It is a 2x25 1 pitch female pin socket connector DIO AO DIO A2 DIO A4 DIO A6 DIO BO DIO B2 DIO B4 DIO B6 DIO CO DIO C2 DIO C4 Gate 0 DIO C6 Clk 1 Ext Trig 5V Out Vout 0 Vout 2 Aground Vout Vin O Vin 1 Vin 2 Vin 3 Vin 4 Vin 5 Vin 6 Vin 7 5 9 Miscellaneous Signals DIO A1 DIO A3 DIO A5 DIO A7 DIO B1 DIO B3 DIO B5 DIO B7 DIO C1 DIO C3 DIO C5 Gate 1 DIO C7 Out O Tout 1 Dground Vout 1 Vout 3 Aground Vin Vin 8 Vin 9 Vin 10 Vin 11 Vin 12 Vin 13 Vin 14 Vin 15 This connector provides access to common auxiliary signals used in a PC application Ground IDE LED NC Reserved Speaker Reset 5V Power LED LCD Backlight Ctrl 5V The signals on this connector that are used on the panel I O board are described below Speaker Out The signal on thi
13. or 10 100Mbps Ethernet The connector includes the LEDs for link and speed The signals come from the Helios SBC mating Ethernet connector Proper isolation must be maintained on all Ethernet signal routing to meet industry standard signal isolation specifications No ground or power plane should be above or underneath these signals The connector contains two LEDs connected to the Link and 100Mbps signals on the Ethernet SBC mating connecior 6 3 VGA The VGA connector is standard vertical DD15 female connector with industry standard VGA pinout It has 4 40 thread inserts and hex screwlocks The signals come from the Helios SBC mating VGA connector 6 4 USB The USB connectors are 4 vertical metal shrouded type A connectors with industry standard pinout for USB The signals come from the two Helios SBC mating USB connectors 6 5 PS 2 Keyboard and Mouse The PS 2 connectors are 2 vertical Mini DIN 6 connectors with industry standard pinout for PS 2 keyboard and mouse The signals come from the Helios SBC mating PS 2 connector 6 6 Data Acquisition The data acquisition connector is a vertical 50 pin connector with long ejector latches for a mating ribbon cable connector with strain relief The signals come from the Helios SBC mating data acquisition connector and have a 1 to 1 correspondence with that connector pinout Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 10 DIAMOND SYSTEMS 6 7 Serial Ports Th
14. s pin is referenced to 5V Out A small buzzer is connected between this pin and 5V Out Power LED Referenced to 5V Out Does not require a series resistor An LED visible on the outside front panel is connected directly between this pin and 5V Out Reset Connection between this pin and Ground will generate a Reset condition A momentary switch is connected between this pin and ground Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 9 iamonp SYSTEMS 6 SBC I O SECTION TOP SIDE These SBC I O connectors are on the top side of the panel I O board They face out through the enclosure front panel 6 1 Input Power The input power connector is Molex part number 39 30 2045 Each pin has a 6A or greater current carrying Capacity Input power may be supplied either as 5VDC or as Vin The 5V is intended to be switched directly to the PC 104 bus power pins via the external power switch The Vin is intended to be switched to an auxiliary connector on the back side of the board which is used to connect to a DC DC power supply The output of the DC DC power supply is then fed either to the PC 104 bus power pins if the power supply is on the PC 104 bus or back to the panel I O board and then to the Helios SBC through the 5V pins on the SBC mating power input connector Vin Ground Ground 5V In 6 2 Ethernet The Ethernet connector is a vertical metal shielded Hl Ab jack with industry standard pinout f
15. te 1x2 1 pitch friction lock connector for connection to a DC DC power supply mounted inside the enclosure The 5VDC output of this DC DC power supply then has two paths to the Helios SBC 1 It can connect directly to the PC 104 bus of the system if the power supply is mounted on the bus or 2 It can be routed back to the panel I O board with another connector and then to the Helios SBC through the panel I O board s pin socket connection The panel I O board also provides a path for optional 12VDC output from the power supply to the Helios SBC through the pin socket The power section contains a green LED which is connected to the 5VDC signal to indicate power status Helios Panel I O Board User Manual Rev A 01 www diamondsystems com Page 6 iamonp SYSTEMS 5 SBC I O SECTION BOTTOM SIDE All these connectors are on the bottom side of the panel I O board Their locations and pinouts match exactly the corresponding connectors on the Helios SBC The pin numbering of these connectors when facing the connector is reversed from the pin numbering on the male pin headers 5 1 Ethernet TX TX NC RX RX NC Link LED Ground Key Duplex 5 2 Input Power 5V 5V 5V Ground Ground Ground 12V 12V The power signals on this connector come from either the front panel input power connector or from a connector leading to the output from a DC DC power supply installed in the system 5 3 PS 2 Keyboard Mouse This conn
16. the SBC input connector 2 Vin 8 30VDC from the input power connector to a connector leading to an internal DC DC power supply whose output is driven directly onto the PC 104 bus using the PC 104 bus connectors on the DC DC power supply The Vin may be routed to the power supply connector either through the front panel switch or through a direct connection 3 Same as 2 above except the 5VDC and optional 12VDC outputs of the DC DC power supply are routed back to the panel I O board and then connected to the Helios SBC through the SBC power input connector The input power connector J24 is connected to a power source where the voltages are determined by the desired method of operation It the front panel switch is not connected to J25 for 5V operation then a bypass jumper consisting of a0 ohm 1 4 watt through hole resistor should be installed at location R149 If the 12V option is desired 12VDC is supplied at the input connector J24 and a bypass jumper consisting of a0 ohm 1 4 watt through hole resistor should be installed at location R150 Ifa Vin voltage between 8 and 30VDC is connected to J24 then either the front panel switch should be connected at J23 or a bypass jumper consisting of a 0 ohm 1 4 watt through hole resister should be installed at location R151 and no jumper is installed at location R150 Front panel switch To either Vin or 5V switch connection DS D ek A Panel Power Input Vin switch connection J23 DC D
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