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1506 and 1507 - Pro

1. Figure 3 1 Fan Assembly Caution Do not operate the 1506 or 1507 without a fan filter Dust build up could cause the unit to malfunction Recommended Hard Drive Preventive Maintenance Pro face has recognized that hard drive failures may begin to increase an average of four to five years into the life of most computers used in industrial applications Therefore it is our recommendation as a preventive maintenance measure that all hard drives used in these types of applications be replaced before the four to five year time period to avoid any down time related to hard drive failure Pro face believes it is important to keep our customers informed to offer alternative solutions and to provide all of our customers with the excellent service they deserve Any questions regarding this issue may be directed to our support center at support profaceamerica com Note Pro face recommends frequent backups of your hard drive especially before beginning preventive maintenance procedures 28 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 3 Maintenance Repair Program Pro face s Product Repair amp Customization Department PR amp C restores equipment to normal operating condition and implements engineering changes that enhance operating specifications Pro face tests products returned to Pro face with the standard Pro face test diagnostics Follow the steps
2. 177 8 8x 0 40 6x 10 2 d 10 72 9 92 9 24 272 3 252 0 234 7 9 60 243 8 11 39 289 0 12 78 324 6 All dimensions in inches mm Figure 2 2 1506 Horizontal Mounting Dimensions 13 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation 1507 Mounting Dimensions Figure 2 3 shows the vertical mounting dimensions for the 1507 Node Box Figure 2 4 shows the horizontal mounting dimension for the 1507 Node Box 2x 11 40 Gx 3858 2x 289 56 2x 11 40 2x 11 400 2x 289 56 2x 289 56 16 16 410 48 17 27 438 66 All dimensions in inches mm Figure 2 3 1507 Vertical Mounting Dimensions 14 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation 2x 11 4 2x 289 6 16 16 i 2x 11 4 ie ek 1 2x114 05 289 8 j 2x 289 6 09 12 7 I 4x 0 2 22 86 I j I I 4x 5 08 i 8x 0 2 i 7403727 8x 5 08 0 4 10 18 4 LA Bx 0 2 rae Pd a a 10 18 9 98 __ 253 5 9 18 1 233 17 17 18 436 37 All dimensions in inches mm Figure 2 4 1507 Horizontal Mounting Dimensions 15 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation Power Management The following paragraphs explain the system power the power supply and the effects of excessive heat electrical noise and line voltage variation of the 1506 and 1507 Node Boxes System Power Using isolation t
3. 41 parallel ss ede Had od ee ee Ms 7 41 PMNS rs cor ee toh tele a 7 Solicita a ita a 7 A O EOS 8 Power SSI Mara Re ae 16 Power SUD PIN oia 16 Power switch iisa eet hdl a A eid sede 25 Preparing the system eseeeesseeeeeseeeeeeeneeereeaes 10 Preventive maintenance ceecee 27 Generals E E NINE Eee 27 h rd Ke TAN AE EEEE E E EE 28 Printer PO A 7 Repairs and service c ocooccccnnoncccnanancnononcnonnnancnnnnnnos 29 Returning a Unit to Pro face cecer 29 Safety agency approval cocoocconnccccncccnnccnoncncnnnncnninns 21 Serial port CONNECTIONS oooconoccnocccoccncnnccnancncnnncnnncnnno 43 Senak POMS iia dt 7 Service and repairs oocoococnnccconccconccconannonononnnninncnons 29 48 System MAINTENANCE ccccccccnnnnncnnnnnnnnnnnnnnnnnnnononononononononos 25 operation EEE SEE eN Me 25 System components Fr nt pane iii a 3 System Power cccceeeeeeeseeeseeeteseeeseeeeeseeeseeeeeeeeens 16 VGA CONNECTOL siensia e aae 43 VIGGO drivers ceci 35 Video EXPANSION anann 35 VIGGO PO ls ders tied ees endo 8 143095 D 143095 D Xycom Automation LLC Canada Sales 905 607 3400 Pro face 750 North Maple Rd Northern Europe Sales 44 1604 790 767 COM Saline MI 48176 Southern Europe Sales 39 011 770 53 11 Phone 734 429 4971 Fax 734 429 1010 http www profaceamerica com 143095 D
4. a time COM2 is the male 25 pin DB connector An external push button reset option and alarm feature is available Consult the AIM3 CPU manual for the jumper that controls this option The keyboard port is a PS 2 stacked mini DIN so a PC AT keyboard can be attached at the side of the unit The keyboard port on the side of the unit is the lower connector Warning To maintain a safe condition do not use an external keyboard and or mouse port when the unit is operating in a hazardous environment 7 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction Table 1 1 1506 and 1507 I O Panel Feature Description III Mouse Port The mouse port is a PS 2 stacked mini DIN that allows you to attach a mouse at the side of the unit Warning To maintain a safe condition do not use an external keyboard and or mouse port when the unit is operating in a hazardous environment Video Port The video port is a 15 pin D sub VGA connector at the side of the unit This connector supports any standard VGA connection Both the LCD flat panel and video port are active as a default at boot time if video display devices are connected to them USB The duplex Universal Serial Bus USB port provides connectivity for USB 1 1 peripherals and hubs Ethernet Port On board 10 100 Base T RJ 45 Ethernet connector Removable This option allows external access to Type or Type Il CompactFlash for CompactFlas solid sta
5. below to prepare the unit for shipment 1 Obtain an Return Merchandise Authorization RMA number for your unit by calling your nearest Pro face Repair Department or Xycom Automation LLC at 734 429 4971 2 Please have the following information Dy EA Company name shipping and billing address Type of service desired product repair or product exchange Product model number part number quantity serial number s and warranty status Failure mode and failure systems Purchase order number or repair order number Attach failure information to the unit to speed processing Place the unit securely in its original packaging or an equivalent heavy duty box Mark the RMA number on your purchase order and on the outside of the box Send the unit to the address given when you receive your RMA number 29 143095 D Chapter 4 Troubleshooting Diagnostic Testing If you suspect that you are having hardware problems with your 1506 or 1507 system you can use the Pro face Xycom diagnostic utility to check out the PC s various ports and subsystems The diagnostic utility is on the Documentation and Support Library CD included with your unit Create Diagnostic Disk The first task is to create a diagnostic diskette The following steps can be done on any computer with a CD ROM drive and a floppy drive 1 2 3 Create a DOS bootable diskette Create a temporary folder on the computer hard drive There is a self extractin
6. computer card cage mass storage and power supply in a truly industrial form The processor board combines all the functions of a complete PC AT compatible computer on a single industrially hardened circuit board Refer to the AIM3 CPU manual for more information on processor and hardware features Standard Features The 1506 and 1507 units come standard with the following features Wall or shelf mountable Flash BIOS Intel Socket 370 Celeron or Pentium II options up to 1 26GHz 100MHz or 133MHz front side bus depending on the processor type 1506 Four AT bus expansion slots e One length PCI e One length PCI e One 3 4 length ISA e One length PCI or ISA slot 1507 Four AT bus expansion slots e One length PCI e One full length PCI e One full length ISA e One full length PCI or ISA slot AGP graphics with base 4 MB system RAM e Automatically shares up to 32 MB with system RAM Up to 512 MB DRAM 20 GB removable hard drive Floppy drive CD ROM IBM PS 2 keyboard port and mouse port 1 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction Two serial COM ports e RS 232 e RS 232 or RS 485 Parallel port and VGA port Two USB 1 1 ports MS DOS operating system UL Listed for use in Class I Division 2 hazardous locations Optional Features Following are optional available features of the 1506 and 1507 Higher capacity IDE hard drives and solid state drives Var
7. information about any different RS 485 connectors COM1 COM is a dual 9 pin connector Table C 5 COM1 Connector Pinout RS 485 Pin Signal 1B TXD 2B TXD 3B TXD TERM 4B TXD TERM 5B GND 6B RXD 7B RXD 8B RXD TERM 9B RXD TERM 42 143095 D 1506 1507 Industrial PC AT Computer Systems Appendix C Pinouts Technical Note For TXD termination connect a 1500 Y watt resistor from pin 3B to pin 4B with pin 1B connected to pin 3B and pin 2B connected to pin 4B For RXD termination connect a 1500 12 watt resistor from pin 8B to pin 9B with pin 6B connected to pin 9B and pin 7B connected to pin 8B COM2 COM2 is a 25 pin connector Table C 6 COM2 Connector Pinout RS 232 Signal Pin ORB_GND 14 TXD2 15 RXD2 16 RTS2 17 CTS2 18 DSR2 19 GND 20 DCD2 21 NC 22 NC 23 PB RESET 24 NC 25 NC VGA Connector The VGA connector is a 15 pin connector Table C 7 VGA Connector Pinout Signal Pin Signal GREEN fio NC E ORB_GND 13 ORB_GND 14 ORB_GND 15 DDCCLK 8 ORB_GND 43 143095 D APPENDIX D AIM3 CONTROLLER JUMPERS Table D 1 Controller Jumpers Jumper Position Function JP1 Not used Not stuffed JP2 JP3 JP4 JP6 1 2 Provide ground return for 12V 5V on COM2 connector 2 3 V Do not provide ground return for 12V 5V on COM2 connector JP7 1 24 Allow high side alarm functi
8. operating system refer to the Pro face Xycom Workstation Recovery Media Software Installation Instructions for Microsoft Windows 98 shipped with systems preinstalled with Windows 98 This document is devoted to the reinstallation of your Microsoft Windows 98 operating system and drivers utilizing the Recovery Media provided with your Pro face Xycom industrial computer Note This procedure assumes that the computer hard disk drive has been completely corrupted or replaced 33 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Warning This procedure will destroy data that may exist on the hard disk drive Windows 2000 Reinstallation If you need to reinstall the Windows 2000 operating system refer to the Pro face Xycom Workstation Recovery Media Software Installation Instructions for Microsoft Windows 2000 shipped with systems preinstalled with Windows 2000 This document is devoted to the reinstallation of your Windows 2000 operating system and drivers utilizing the Recovery Media provided with your Pro face Xycom industrial computer Note This procedure assumes that the computer hard disk drive has been completely corrupted or replaced Warning This procedure will destroy data that may exist on the hard disk drive Windows NT Reinstallation If you need to reinstall the Windows NT operating system refer to the Pro face Xycom Workstation Recovery Media Softwa
9. you will receive the Adaptec ATA RAID 1200A Installation and User s Guide and the Adaptec RAID driver disk These items will help you to understand and use your RAID Enabled PC The Installation and User s Guide covers e Installation of the Adaptec controller e Using the BIOS array Configuration Utility e Installation of the device driver e Using the ATA RAID management software There is also a troubleshooting section to assist you with any questions that may arise You may also contact Pro face Technical Support at support profaceamerica com or 734 944 0482 for assistance 46 143095 D Index AIM3 JUMPE Sih Atlant a a id eden den 44 Cable communication cable interface 1 25 Connections Avis weasel dada 25 Class I locationS cccii iid ie 23 Class Il locations i susende skeer hebr 23 COMP Orsa nere e 7 COMA COMMECTOFccccnocccnccccnoncnancnonnnanancnnnncncnncncnncnnns 43 Connectors AIM3 COME srt wr aot a we 42 parallel port ccoo 41 VGA conil aeist 43 keyboard econ ante ea ae eels 41 MOUSE Ss ii hhc teehee ee oes Seah nok Ste ot BEL hos 41 Definitions class and division 23 A E 20 Division 1 locations s e 23 Division 2 locations snien n n a AnA dne 24 Documentation Kit ooooonccccnnoccconanaccnonencnonanancnnnan ono 8 A es ee ie set Baath a ote a 20 Drivers InstalliNG otitis AAT eole 35 miscellaneous eeeeeceeeseeeeeeeeeeeeensteeeeeseneeeenseee 36 VIE i E cies span Na rn DE 35 Dual In
10. 1506 and 1507 EEE A AAA A Al Industrial PC AT Node Box Systems User Manual O 2007 XYCOM AUTOMATION LLC Printed in the United States of America 1506 1507 Industrial PC AT Computer Systems Revision Record Revision Description Date A Manual Released 9 03 B DC Power Supply Information added to 1507 9 04 C RAID Enabled Appendix added 10 04 D Name change correct where applicable with document 4 07 Part Number 143095 D Trademark Information Xycom and Xycom Automation are trademarks of Xycom Automation L L C Xycom Automation L L C now is referred to as Pro face through a D B A The Pro face name and logo will replace the Xycom name and logo on all documents where possible Pro face is a trademark of Digital Electronics Corporation Brand or product names are trademarks or registered trademarks of their respective owners Intel and Pentium are registered trademarks and Celeron is a trademark of Intel Corporation Windows Windows NT and Windows XP are registered trademarks of Microsoft Corporation in the U S and in other countries Copyright Information This document is copyrighted by Xycom Automation L L C Xycom and shall not be reproduced or copied without expressed written authorization from Xycom Automation L L C The information contained within this document is subject to change without notice Pro face does not guarantee the accuracy of the information United States FCC Part 15 Subpart B Class A EMI Co
11. 7 CFR Part 15 Class A Compliance CE EMI EN55022 Class A IMMUNITY EN61000 6 2 SAFETY EN60950 HARMONICS EN61000 3 2 Class A FLICKER EN61000 3 3 38 143095 D 1506 1507 Industrial PC AT Computer Systems Appendix A Technical Specifications Environmental Specifications Table A 2 lists the environmental specifications for the 1506 and 1507 Industrial Node Box systems Table A 2 Environmental Specifications Characteristic Specification Temperature Operating 0 to 50 C 82 to 122 F Non operating 20 to 60 C 4 to 140 F Humidity Operating 20 to 80 RH noncondensing Non operating 20 to 80 RH noncondensing Altitude Operating Sea level to 10 000 feet 3 048 m Non operating Sea level to 40 000 feet 12 192 m Vibration 5 2000 Hz Operating 0 006 0 15mm peak to peak displacement 1 0g maximum acceleration Non operating 0 015 0 38mm peak to peak displacement 2 5g maximum acceleration Shock Operating 15g peak acceleration 11 msec duration Ya Non operating 918 wave 30g peak acceleration 11 msec duration 1 2 sine wave Consistent with internal component specifications These values are with solid state hard drives and not rotating media drives 39 143095 D Appendix B AC Model Block Diagram DIMM MEMORY CONN E PARALLEL PORT mA CPU BOARD 4 SLOT BACKPLANE Figure B 1 1506 1507 System Block Diagra
12. 7 Industrial PC AT Computer Systems Chapter 2 Installation e Underwriters Laboratories Inc UL 508 Industrial Control Equipment UL Listed File E107636 e Canadian Standard Association Specification C22 2 No 213 M1987 Non incendiary electrical equipment for use in Class I Division 2 Hazardous Locations cUL Listed File E180970 e Canadian Standards Association Specification C22 2 No 142 CUL Listed File E107636 Warning Suitable for use in Class I Division 2 Groups A B C and D hazardous locations or non hazardous locations only Warning Explosion Hazard Substitution of components may impair suitability for Class Division 2 Avertissement Risque d Explosion La substitution de composants peut rendre ce materiel inacceptable pour les emplamements de classe Division 2 Warning Explosion Hazard Do not disconnect equipment unless the power has been switched off or the area is known to be non hazardous Avertissement Risque d Explosion Avant de deconnecter l equipment coupler le courant ou s assurer que emplacement est designe non dangereux Warning Explosion Hazard When in hazardous locations turn off power before replacing or wiring modules 22 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation Avertissement Risque d Explosion Dans les situations hasardees couper la courant avant de remplacer ou de cabler les mo
13. B screw from the desired slot Slide the PC AT expansion board into the corresponding rail ie ET KORET nD Push the board into the backplane connectors Caution DO NOT force the boards or apply uneven pressure Caution Make sure boards do not exceed the power limitations of the 1506 and or 1507 Refer to tables 2 2 and 2 3 6 Secure the board by installing the screw through the hole in the board s metal ORB and into the top of the track 20 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation 7 Replace the lid Hazardous Locations Installation Pro face Xycom designed the 1506 and 1507 Node Box Industrial PCs to meet the requirements of Class I Division 2 Hazardous Locations applications Division 2 locations are those locations that are normally non hazardous but could become hazardous due to accidents that may expose the area to flammable vapors gases or combustible dusts These systems have been designed as non incendiary devices They are not intrinsically safe and should never be operated within a Division 1 normally hazardous location when installed as described here Nor should any peripheral interface device attached to these systems be located within Division 1 locations unless approved and or certified diode barriers are placed in series with each individual signal and DC power line Any such installations are beyond the bounds of Pro face design intent Pro face accepts n
14. Cable A power cable must be created to supply power to the unit The following materials are needed e A three position power connector supplied e A braid foil shielded power cable terminated at power source end with three 18 1 0 mm 16 1 3 mm or 14 1 6 mm AWG solid or stranded copper wires rated 80 C or better Figure 2 5 1506 1507 AC Power Connector Perform the following steps to construct and attach the cable 1 Cut wire cable to the desired length 2 Strip 0 25 inch 6 mm of insulation from the end of the conductor wire No bare wire should be exposed when the cable is connected to the workstation 18 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation 3 Tin the wire ends with solder if using stranded wire This will keep the wire from fraying Warning When inserting the wire ends of the power cable into the block plug be sure there is no exposed wire Trim the wire ends of the cable or cut a new cable if necessary Figure 2 6 Internal View of 1506 1507 AC Power Connector 4 Insert the three wire ends of the power cable into the hole of the connector plug Bend the Protective Earth ground PE wire the neutral N wire and the line L wire around the corresponding screw Be sure that no bare wires are exposed 5 Tighten the three screws above the wires to hold them firmly in place Warning Never tighten the three screws of the block plug when the ca
15. a or redundant hard drives Many of Pro face Xycom s Heavy Duty Industrial PCs offer solid state media in the form of CompactFlash or solid state hard drives While many storage sizes are available the cost of solid state drives escalates considerably as the required drive size increases A second approach is to use RAID RAID stands for Redundant Array of Independent Disks In essence RAID is two or more hard drives hooked up to the same controller either SCSI or IDE The RAID controller can stripe or mirror data Striping RAID 0 is used to read and write to many disks at once to increase hard drive performance while mirroring RAID 1 allows the same data to be available on two or more drives There are two methods to implement a RAID solution via software or dedicated hardware Pro face has chosen a hardware solution because software solutions are more limited and require a Windows 2000 or 2003 Server Pro face Xycom s hardware RAID solution utilizes the Adaptec ATA RAID 1200A a PCI IDE RAID controller card This controller card is installed in the PC and the array drives are connected to it instead of to an IDE controller Most PCs use an IDE controller to interface between the system and the hard disks The RAID controller occupies a single PCI slot so you need to verify the available expansion in your Industrial PC for the application RAID 1 with two hard drives was chosen as the optimal solution for creating a mor
16. ble is connected to a power source The screws are conductive and have full contact with the cable wire 6 Use the screw provided to secure and strain relief the power cable inside the connector Plug the power cable into the power supply located on the side of the unit Install the plug retainer bracket over the plug mandatory for hazardous location installations 7 Once the power cable and other optional interface cables are installed installation is complete Note When disconnecting the power cord from the unit be sure to completely loosen the two securing screws on the retainer bracket 19 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation Installing Internal Hardware Options Remove the lid to install internal hardware options Caution Turn off the unit before installing internal hardware Warning Installation of expansion boards may void safety and or EMC compliance DRAM and Additional DRAM Dual Inline Memory Modules DIMMs You can order the 1506 and 1507 systems factory configured for many configurations of DRAM You can reconfigure the DRAM capacity by changing the DRAM DIMMs on your board For more information refer to the AIM3 CPU manual PC AT and PCI Boards 1 Check the memory and I O configuration of the board you want to install so that it does not conflict with the CPU and I O memory maps in your AIM3 CPU board manual Remove the lid Remove the OR
17. communication cables should include a chassis ground shield This shield should include both copper braid and aluminum foil The D sub style connector housing should be a metal conductive type e g molded zinc and the ground shield braid should be well terminated directly to the connector housing Do not use a shield drain wire The outer diameter of the cable must be suited to the inner diameter of the cable connector strain relief in order to ensure that a reliable degree of strain relief is maintained Always secure the D Sub connectors to the workstation mating connectors via the two screws located on both sides 25 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation Warning Never connect or disconnect the communication cables while power is applied at either end of the cable This may result in an incendiary spark Permanent damage to the workstation communication components may occur Operation and Maintenance The systems have been designed for compliance with relevant spark ignition tests However please note that the workstation front panel contrast adjustment tactile switches and keyboard connector are the only make break components intended to be exercised by the operator in the course of normal operation Warning In order to maintain a safe condition never use an external keyboard or mouse when the unit is operating in the presence of a hazardous environment With respect to Hazard
18. cture such as a steel support beam Each different apparatus should be connected to a single Earth Ground point in a star configuration with low impedance cable Scrape away paint and other nonconductive material from the area where a chassis makes contact with the enclosure e In addition to the ground connection made through the mounting bolt or stud use a one inch metal braid or size 8 AWG wire to connect between each chassis and the enclosure at the mounting bolt or stud 1506 Power Supply The 1506 node box has a 90 watt AC power supply with 38 watts maximum of available expansion power The expansion power is limited as shown in Table 2 1 16 143095 D Table 2 1 1506 Available Expansion Current 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation Voltage Available Current 3 3 VDC 4 0A 5 0 VDC 5 7A 5 0 VDC 160mA 12 0 VDC 0 58A 12 0 VDC 160mA Caution 5V and 3 3V combined shall not exceed 28 watts 5V and 12V combined shall not exceed 2 watts 1507 Power Supply The 1507 node box has a 200 watt AC power supply with 66 watts maximum of available expansion power The expansion power is limited as shown in Table 2 2 Table 2 2 1507 Available Expansion Current Voltage Available Current 3 3 VDC 10 0A 5 0 VDC 12 0A 5 0 VDC 0 2A 12 0 VDC 4 9A 12 0 VDC 0 5A Caution 3 3V and 5 0V combined shall not exceed 66 wa
19. dules Definitions The following Class and Division explanations are derived from Article 500 Sections 5 and 6 of the United States National Fire Protection Agency National Electric Code NFPA 70 1990 They are not complete and are included here only for a general description for those not familiar with generic hazardous locations requirements Persons responsible for the installation of this equipment in Hazardous Locations are responsible for ensuring that all relevant codes and regulations related to location rating enclosure and wiring are met Class Locations Class I locations are those in which flammable gases or vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures Class II Locations Class II locations are those that are or may become hazardous because of the presence of combustible dust Division 1 Locations A Division 1 location is one in which flammable or ignitable gasses vapors or combustible dusts and particles can exist due the following conditions e Normal operating conditions e Because of repair maintenance conditions leakage or mechanical failure or abnormal operation of machinery or equipment or e Combustible dusts of an electrically conductive nature may be present in hazardous quantities Note Pro face systems are not suitable for installation within Division 1 locations 23 143095 D 1506 1507 Industrial PC AT Com
20. e robust fault tolerant system in the Pro face Xycom 1507 3700 Series and 1600 Series of Heavy Duty Industrial PCs Pro face has chosen to support Windows 2000 and Windows XP for these RAID enabled assemblies for optimal and reliable performance In a RAID 1 system there is a primary and a secondary hard drive The RAID controller writes to both drives but only reads from the primary drive If the RAID controller detects any problems with the primary drive it switches over to the 1 ATA and IDE are used interchangeably in this context IDE stands for Integrated Drive Electronics ATA stands for Advanced Technology Attachment Both terms refer to the type of controller used in PCs 45 143095 D 1506 1507 Industrial PC AT Computer Systems Appendix E The RAID Enabled PC secondary drive which has an exact copy of all data on the primary drive and informs the operator of the switchover If the RAID controller should detect any problems with the secondary drive it stops writing to it and informs the operator of the problem In either case the operator can schedule a time to replace the failed drive Note The RAID Enabled Industrial PC is configured at time of manufacture The RAID controller is not available as a user installable upgrade When you order a RAID enabled Industrial PC the Adaptec controller will be installed and configured in the unit at the Pro face plant And in addition to the items listed in Chapter 2
21. ed for use in hazardous locations must include a group rating Various flammable and combustible substances are divided into these groups as a function of their individual maximum experimental safe gap MESG explosion pressure and ignition temperature Component temperatures and the potential for spark based upon voltage current and circuit characteristics within electrical equipment will determine what the equipment group rating will be A device approved for installation within Class I Group A locations may also be used in Groups B C or D Note Approved Class equipment may not be suitable for Class II installations Class includes Groups A B C and D Class II includes Groups F and G Enclosures The systems are designed for installation within a clean and dry enclosure for both ordinary and hazardous locations The enclosure used for Class I hazardous 24 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation locations should have a minimum rating of Type 12 NEMA 12 IP 5X However Type 4 IP 6X enclosures are strongly recommended The requirements for enclosure fittings conduit and wiring vary according to the specific rating of the location and the type of flammable or combustible material involved Those requirements are beyond the scope of this document and it is the responsibility of the customer to ensure that their installation is compliant with codes and regulations that app
22. filter with warm water and dish soap and let it air dry Do not scrub the filter and do not reinstall it into the unit until it is completely dry Base your maintenance schedule on the type of environment the system is in i e if the area is dusty you should schedule maintenance more often than if it is a dry clean area Check the filter often to determine if it needs to be changed ahead of schedule Remove dust and dirt from PC components If dust builds up on heat sinks and circuitry an obstruction of heat dissipation could cause the unit to malfunction If dust reaches the electronic boards a short circuit could occur Check the connections to I O modules especially in environments where vibration could loosen the connections Check to see that all plugs sockets terminal strips and module connections are solid Remove unnecessary articles such as drawings or manuals from the unit They can obstruct airflow and create hot spots which cause the system to malfunction Do not place noise generating equipment near the 1506 or 1507 unit Fuse Replacement The 1506 and 1507 units have no accessible fuse Return the unit to the factory for fuse replacement Fan Filter Replacement To change the fan filter remove the grill and filter as illustrated in Figure 3 1 and replace the filter Then snap the assembly back into position 27 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 3 Maintenance
23. g zip file on the Documentation and Support Library CD located in DRIVERS Computer Diagnostics 99290 001 DOS xydiag Run that program and extract the files to the temporary folder you just created Copy the extracted files onto the DOS bootable diskette This diskette will be inserted directly into the 3700 unit s floppy drive Prepare the System Before starting the system tests perform the following steps 1 4 Place the CPU board jumpers and switches to the factory set positions Refer to the AIM3 CPU manual for these settings Plug the female end of the AC power cable into the side of the unit and the male end into a properly grounded outlet Connect the serial loopback connector s and the printer cable to the appropriate connectors and connect a PC AT or PS 2 keyboard Figure 4 1 illustrates the wiring necessary for the loopback connection Default the CMOS setup to the factory settings After completing all of the preceding steps the 3700 unit is ready for diagnostic testing Follow the directions in the Running the Tests section of this chapter 30 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 4 Troubleshooting 1 3 4 50 0 On O Com 1 RS 232 Serial Loopback Connections Com 2 RS 232 Serial Loopback Connections Figure 4 1 Serial Loopback Connections 31 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Running the Tests To r
24. h as dust and moisture Metal enclosures also help minimize the effects of electromagnetic radiation that nearby equipment can generate For Underwriters Laboratories UL compliance the unit must be installed within a suitable fire enclosure Read the following sections carefully to be sure that you are complying with all the safety requirements 1 Select a NEMA rated enclosure and place the unit to allow easy access to the system ports see other sections in this chapter and Appendix A e To assure a NEMA 4 seal choose an approved enclosure that has a 14 gauge 0 075 in 1 9 mm thick steel or 0 125 in 3 2 mm thick aluminum front face e Be sure to account for the unit s depth when choosing the depth of the enclosure 2 Create a cutout in the enclosure see System Mounting Dimensions e Be sure to place the unit at a comfortable working level Make sure the area around the cutout is clean and free from metal burrs 3 Mount the unit in an upright position and properly secure the unit into the panel e Tighten the fourteen 10 nuts to 25 inch pounds 2 8 Newton meters 28Kgf cm 4 Construct a power cable following the instructions in AC Power Cable in this chapter 10 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation 5 Attach one end of the power cord to the power receptacle on the unit and the other end to a properly grounded 115 230 VAC 50 60 Hz outlet A ground path from the uni
25. ion cable connectors must be metal ideally zinc die cast backshell types and provide 360 degree protection about the interface wires The cable shield braid must be terminated directly to the metal connector shell ground drain wires alone are not adequate Protective measures for power and interface cables as described within this manual must be applied Do not leave cables connected to unused interfaces or disconnected at one end Changes or modifications to this device not expressly approved by the manufacturer could void the user s authority to operate the equipment EMC compliance is in part a function of PCB design Third party add on AT XT peripheral PCB assemblies installed within this apparatus may void EMC compliance FCC CE compliant PCB assemblies should always be used where possible PRO FACE can accept no responsibility for the EMC performance of this apparatus after system integrator user installation of PCB assemblies not manufactured and or expressly tested and approved for compliance by PRO FACE It is the responsibility of the system integrator user to ensure that installation and operation of such devices does not void EMC compliance 143095 D Table of Contents CHAPTER 1 INTRODUCTION iia asentando latinas lorotonafiicaais 1 PRODUCT OVERVIEW aia 1 SANA RARO ITESO de etait ee 1 Optional Features 0 A A EAEE 2 MOUNTING PLATES cion A a a Ea 3 1506 Mo nting Plate A a it 3 1907 MOUNTING Platera eai areia da se cosets ed
26. ious processor speeds Preinstalled Microsoft Windows 98 or Windows NT or Windows 2000 or Windows XP Professional 9000 USBF USB floppy requires Windows 98 2000 or XP Secondary IDE Drive Options choice of one e Externally accessible CompactFlash options up to 512MB e 2 5 Dual hard drives e External Drive bay connector for 9000 XBAY 9000 XBAY sold separately 24VDC power supply on 1507 units only The figures and tables on the next several pages illustrate the internal and external components on the front and back panels of the unit to help you locate the features of the 1506 and 1507 Node Boxes 2 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction Mounting Plates The following figures illustrated the mounting plates for the 1506 and 1507 systems 1506 Mounting Plate The 1506 mounting plate protects the system s interior when the system is properly mounted Mounting Plate I O Panel Figure 1 1 1506 Mounting Plate 3 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction 1507 Mounting Plate The 1507 mounting plate protects the system s interior when the system is properly mounted Mounting Plate I O Panel Figure 1 2 1507 Mounting Plate 4 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction Back Panels and Power Panels The following figures show the back panel and power
27. line Memory Modules 20 Enclosures 55 i ads 24 FAN SW ae SEEST OSSE SEES Ea 27 filter replacement esseceeeseneereeseeereeeneeeteee 27 Features standard cin a a aah 1 Front panela its oder sadel eden 3 Fuse replacement suis SENSE ER ln 27 Groups wen ln eee e 24 Heat EXCESSIVE sas n ar lands 17 Installation DRAM ra oe ee 20 E abated 35 hazardous locations s e 21 internal hardware c ooooocccnnncccccnoncccnnnoncnonanancnnnnnoss 20 Operating SYSteMS ocoonoccccnonccccononcnonanancnonanoss 32 33 PC AT and PCI boardS cooococccccccocinccccnnoccnanccnnnnas 20 Jumper settings AIM3 CPU board ccooocccocccinocaconccioncccnnccnancnnanccnnnnos 44 Keyboard CONNGCIOIS akanan r a tite 41 Keyboard DOM eE ET 7 Line voltage variation oocoonncccccccnnncincccccccnnnccinnnns 18 Maintenance suis a ei 27 O 27 Mar dr ici 28 Mouse port wens Acceiet tarot brand 8 41 Noise electrical ccccccccooonnnnccnnnncononnnnncnnnnnnnnn 17 Operating systems installation ura als 32 Parallel port Connector ooocconocccononoccnononcncnanancnnnnnos 41 PC AT installation and PCI boards 2 20 Pinouts COME ato ero e eo tenes 43 keyboard connector coooocccononcccnnaonnnononcnonanencnnnanoss 41 Mouse CONNECTION cirio Aled lac 41 parallel port ccoo ren Obie eee 41 VGA CONMOCtOTFcccccocccncccconcncnnnnnoncncnnnnnnncnnancnrnncnnns 43 Ports COM ak sisted ei A ee ie 7 keyboard isn sae fies eet de 7 41 MOUS Cres edo cn 8
28. ly to their specific location Reference NFPA 70 Article 500 for specific regulations in the United States Power Switch The 1506 and 1507 systems do not have a power switch The amount of input power required by these systems classifies the power switch as an incendiary device because the voltage and current across the make break device are capable of creating a spark Hazardous locations regulations require that a power switch rated for ordinary locations may be used if it is located in an area specified as non hazardous However limits in cable length between the workstation and the power switch may apply Otherwise the switch must be compliant with Class I Division 1 requirements intrinsically safe These switches are built in a manner that prevents the possibility of a spark when contacts are made or broken Use suitable UL listed and or CSA Certified Class I Division 1 switches in hazardous locations These switches are available from a wide number of sources It is the responsibility of the customer to ensure that the power switch selected for their installation has the correct hazardous locations rating for the location in which it is installed Cable Connections Division 2 hazardous location regulations require that all cable connections be provided with adequate strain relief and positive interlock Never connect or disconnect a cable while power is applied at either end of the cable Communication Cable Interface All
29. m Appendix C Pinouts This appendix provides the pinouts for the keyboard mouse LPT1 COM1 COM2 USB and VGA connectors NC indicates No Connection 40 143095 D 1506 1507 Industrial PC AT Computer Systems Appendix C Pinouts Keyboard Port Connector This connector is a standard PS 2 compatible connector Table C 1 Keyboard Connector Pinout Pin Signal 1A KB_DATA 2A NC 3A GND 4A 5VFUSE 5A KB_CLK 6A NC Mouse Port Connector This PS 2 mini DIN connector allows you to attach a mouse Table C 2 Mouse Connector Pinout Pin Signal 1B MOUSE DATA B NC 3B GND 4B 5VFUSE 5B MOUSE CLK 6B NC Dual USB Connector USB1 USB1 is a dual 4 pin connector Table C 3 Dual USB Pinout Pin Description Pin Description 1A 5VFUSE 1B 5VFUSE 2A USBPO 2B USBP1 3A USBPO 3B USBP1 4A GND 4B GND Parallel Port Connector LPT1 The parallel port connector is a 25 pin DB connector Table C 4 Parallel Connector Pinout Signal Pin Signal STROBE 14 15 16 17 SELIN 41 143095 D 1506 1507 Industrial PC AT Computer Systems Appendix C Pinouts 18 19 20 21 22 23 24 25 Serial Port Connectors Serial ports RS 232 and RS 485 are supported on the 1506 and 1507 Node Boxes Please note that only one connector can be used at a time and that all termination is done outside the unit Refer to the AIM3 manual for
30. mpliance Statement NOTE 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 the user s expense For European Users 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 INSTALLATION Electromagnetic Compatibility WARNING The connection of non shielded equipment interface cables to this equipment will invalidate FCC EMI and European Union EMC compliance and may result in electromagnetic interference and or susceptibility levels which are in violation of regulations applying to the legal operation of this device It is the responsibility of the system integrator and or user to apply the following directions relating to installation and configuration All interface cables must include shielded cables Braid foil type shields are recommended Communicat
31. ng For Hazardous Locations installation review Hazardous Locations Installation in Chapter 2 before startup To prepare the system for use perform the following steps 1 2i 3 Attach optional keyboard to the keyboard port Attach other optional equipment following the instructions in Chapter 2 Check the 115 230 VAC selector switch on the power supply to see that it is set appropriately applies only to 1506 units Attach the power cord from the power receptacle to a properly grounded 115 230 VAC 50 60 Hz outlet See Chapter 2 AC Power Cable Turn on power to the unit via an outlet power switch if applicable The system will boot up into the operating system If not pre installed install application software via the floppy the CD ROM or a network 9 143095 D Chapter 2 Installation This chapter offers detailed installation instructions and outlines the options for the 1506 and 1507 Node Boxes The figures on the next several pages show the internal and external components of the units to help you locate features relevant to installation Installation Overview Warning For installation in Hazardous Locations review the Hazardous Locations Installation section in this chapter before startup The rugged design of the 1506 and 1507 Node Boxes allows it to be installed in most industrial environments The system is generally placed in a NEMA 4 4X 12 enclosure to protect against contaminants suc
32. nnnnnnnrnnnnnnonononnrrnnnnnnnononnnennnnnnnnns 28 REPAIR PROGRAM ad vagevelacteeyaue areata duuyuade vate tada dea rails 29 CHAPTER 4 TROUBLESHOOTIN Go sassscscsntnsscscnacecsccncsccencnacccsccncnatcscsavectsccasacesceasecsscsasateseeatecssesevcuuseeavecstencsddcsesaue 30 DIAGNOSTIC ESTING veia e ie ia 30 Create DiagnostiC DISK ai a es s eceeds Aa nun rele raderer forsage 30 Prepare the Systema an a Ee ee ele Betis 30 RUNNING THE TESTS 00 a bat dc E renere baren Es 32 REINSTALLING OPERATING SYSTEMS occccccccncncncncnononononononnnnnnnnnn nn nn nn nn nn nn nn nn nn nn nn nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenenenenenenininans 32 i 143095 D 1506 1507 Industrial PC AT Computer Systems Table of Contents MS DOS ReinStallation 22 etik cards Sereda tela A ein entrede a li at a 33 Windows 98 ReinstallatiOn ccccccecceccecceccsessescssseseescescescssssssssevsecevsucusseassssssessusavuseuseasesssaesssaeteesueteasessesseeass 33 Windows 2000 Reinstallation aan nerne nerve renere n ennen ennen nerne renerne 34 Windows NT Reinstallatio na aaene urene nerne renee nen nerne nerne renerne renerne renerne 34 Windows XP Reinstallation a rrrernreee 35 INSTALLING DRIVERS fei mni a a eara aae le dd tdt ere ist 35 VMIACODEVEES di ias ES 35 VIO EXPANSION iba 35 MISCOENZANCOUS DIVA os 36 APPENDIX A TECHNICAL SPECIFICATIONS uses 37 HARDWARE SPECIFICATIONS ua inici 37 ENVIRONMENTAL SPECIFICATIONS 4 cau teecouesezacxctucecccdussussz causue
33. nstall a current operating system refer to the operating system s manual for directions Installing Drivers This section describes how to install the drivers associated with the system Video Drivers Video drivers and the expansion utilities are on the Documentation and Support Library CD included with the documentation kit For the AIM3 system choose the video driver for your operating system from the following directory on the Documentation and Support Library CD DRIVERS VIDEO AIM3 142338 Video Expansion This section deals with the hardware expansion capability of the video controller chip in DOS applications Note It is not necessary to read this section if you are a Windows or OS 2 user and do not plan to run DOS applications 35 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Unlike a CRT monitor a flat panel display has a fixed horizontal and vertical resolution There are many DOS video modes whose resolution is less than that of a flat panel display In order to more efficiently make use of the flat panel display s active area it is necessary to employ an expansion technique which stretches the lower resolution information to fill the higher resolution of the display For example DOS defaults to VGA video mode 3 This is an 80 column 25 row text only screen whose effective resolution is 640 dots x 400 scan lines Because of this the 800 x 600 display of the s
34. o responsibility for installations of this equipment or any devices attached to this equipment in Division 1 locations Note It is the customer s responsibility when adding additional cards that they meet operating conditions for Class Division 2 hazardous locations Additions and or modifications without express consent from UL and or Pro face will void Hazardous Locations compliance It is the responsibility of the customer to ensure that the product is properly rated for the location If the intended location does not presently have a Class Division and Group rating then users should consult the appropriate authorities having jurisdiction in order to determine the correct rating for that Hazardous Location In accordance with Federal State Provincial and Local regulations all hazardous locations installations should be inspected by the appropriate authority having jurisdiction prior to use Only technically qualified personnel should install service and inspect these systems Warning In order to maintain a safe condition do not use an external keyboard or mouse when the unit is operating in a hazardous environment Safety Agency Approval The Pro face systems have the following approvals e Underwriters Laboratories Inc UL 1604 Standard for Safety Electrical equipment for use in Class I and Class II Division 2 and Class II hazardous classified locations UL Listed File E180970 21 143095 D 1506 150
35. on on COM2 connector 2 3 Do not allow high side alarm function on COM2 connector JP8 1 24 Allow low side alarm function on COM2 connector 2 3 Do not allow low side alarm function on COM2 connector JP9 1 2 Supply 12V to COM2 connector 2 3 V Do not supply 12V to COM2 connector JP10 1 2 Supply 5V to COM2 connector 2 3 V Do not supply 5V to COM2 connector JP11 1 2 Allow external reset from COM2 connector 2 3 V Do not allow external reset from COM2 connector JP12 1 2 BIOS detects 40 cond cable UDMA33 max Primary IDE 2 3 V BIOS detects 80 cond cable UDMA66 100 max Primary IDE JP13 1 2 V BIOS detects 40 cond cable UDMA33 max Secondary IDE 2 3 BIOS detects 80 cond cable UDMA66 100 max Secondary IDE JP14 1 2 CD ROM is master on primary IDE 2 3 V CD ROM is slave on primary IDE JP15 1 2 V Normal operation 2 3 Clear CMOS JP16 This is not a jumper It allows Arium Emulator to reset the board indicates default jumper setting 44 143095 D Appendix E The RAID Enabled 1507 IPC Option Note The RAID enabled option is only available on the 1507 Node Box The component most susceptible to shock and vibration in any Industrial PC is the hard drive Some sources suggest shock mounting the hard drive unfortunately shock mounting may cause the hard drive to become more vibration sensitive at certain frequencies The most common methods to overcome a susceptibility to vibration are through the use of either solid state storage medi
36. ons Seats Specification Characteristic p 1506 1507 Mechanical Height 9 24 de Width 11 39 EB Depth 5 48 Weight 13 Ibs 18 Ibs Electrical 100 132 200 240 VAC 100 240 VAC AC 50 60 Hz switch selectable 50 60 Hz auto ranging 4 0A maximum 5 0A maximum i 19 36VDC 4 4A typical DC Not available i 19 VDC 7 Caution For the 1507 4 4A typical 19 VDC does not include power for the expansion slots Power Supply AC 90 watts 200 watts DC Not available 300 watts Passive Backplane one Y length PCI one Ye length PCI expansion slots p one length ISA one full length ISA one length ISA or PCI one full length ISA or PCI Power available for 33VW 4 0A 33VW 10 04 o o TE 5V 120A units 5 V 160mA 5 V 0 2A 12 V 0 58A 12V 49A 12 V 160mA 12 V 0 5A Caution 1506 5V and 3 3V not to exceed 28 watts total 5V and 12V not to exceed 2 watts total 1507 3 3V and 5 0V power combined shall not exceed 66 watts Power available for Not available 3 3V 9A expansion in DC 45 V 7A units 5 V 0 54A 12V 8A 12 V 0 7A 37 143095 D 1506 1507 Industrial PC AT Computer Systems Appendix A Technical Specifications Table A 1 Hardware Specifications Specification 1506 1507 Caution 5V and 12V combined cannot exceed 0 8 amps Characteristic Agency Approvals UL 508 Listed UL 1604 Listed cUL CSA C22 2 No 142 Listed CUL CSA C22 2 No 213 Listed Regulatory FCC 4
37. ooooooonocccnonocicinnnocacononcccnnnoncncnnnrncnonarnnnnn 20 POAT BAG RCMB GANAS nas E e ae hace eal saline an Anata Ue ia nae tt th ah Mes 20 HAZARDOUS LOCATIONS INSTALLATION cccccccssesseccecceccesessececcceceeensceceeeeeceusseseceeessueeaseceeseeseuaesseceeeeetsaaeaseceeeeensaansecess 21 SAFETY AGENCY APPROVaALecoconononononononononononononononnnonononoronorororonononorornrnnonnn nro nn nor nnn nono rn nono no nono rn ron nro REEERE nono nono rororonnnnns 21 DOMINIOS A A a e AN A Ne 23 Class PEOCA ION da ra load n bea 23 CES 23 DIVISION 1 LOCATIONS nerse A EA iUseuuvasvadedaadeverevavrideetes 23 DIVISION A Ba leteti e a Sisi ds EE S E id AAA AA E E E E 24 COUPE Sula da da boda a vacates E AE O a T EGETO 24 ENCLOSURES EAE a td EEA T A E EAE ETT EOE 24 POWER SWITCH 0 nt A A a A E a A TA ae TA RN 25 CABLE CONNECTIONS Aesop a antaa aa a E E toca i Ra E a E Ai AAEE AE es 25 Communication Cable Interface cococcccccccncncnccnnnnonononononenonenonnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonenenencnnnnnnnnaninans 25 OPERATION AND MAINTENANCE unitat ED a ok Dec REL eek A 26 CHAPTER 3 MAINTENANCE ici aa 27 GENERAL PREVENTIVE MAINTENANCE cooococononononononononononononononononononononoronononnrnnnrnrnronorororornrn ro nono ro nono nono nono ro nono rnrnrnrnronnnnos 27 Fuse R pla cement iia A A ITA A Ata 27 Fan Filter Replace MENE ii dado 27 RECOMMENDED HARD DRIVE PREVENTIVE MAINTENANCE coccccoooocccnncnncconnonconnnnnonononnrnnnnnn
38. ostic utility will prematurely shorten the life of the drive Reinstalling Operating Systems The 1506 and 1507 systems ship with MS DOS preinstalled Windows 98 Windows 2000 Windows NT and Windows XP Professional operating 32 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 4 Troubleshooting systems are also available If you need to reinstall an operating system refer to the appropriate section below If you want to change operating systems you will need to use the manufacturer s instruction manual Note If you need to reinstall the Windows 98 Windows 2000 Windows NT or Windows XP Professional operating system you must have an internal CD ROM drive or an external parallel port CD ROM drive Windows NT and Windows XP ship only on CD ROM MS DOS Reinstallation If you need to reinstall MS DOS refer to the Proface Xycom Workstation Recovery Media Software Installation Instructions for Microsoft MS DOS 6 2 shipped with systems preinstalled with MS DOS This document is devoted to the reinstallation of your MS DOS operating system and drivers utilizing the Recovery Media provided with your Pro face Xycom industrial computer Note This procedure assumes that the computer hard disk drive has been completely corrupted or replaced Warning This procedure will destroy data that may exist on the hard disk drive Windows 98 Reinstallation If you need to reinstall the Windows 98
39. ous Location installations always observe the following rules 1 Always install the 1506 or 1507 within an enclosure suitable for the specific application Type 4 IP 65 enclosures are recommended even when not required by regulations 2 If present keep enclosure doors or openings closed at all times to avoid the accumulation of foreign matter inside the workstation 3 Never subject the unit to any installation or service procedures unless power has been removed and the area is known to be non hazardous This includes the installation or removal of power cables communication cables or removal of the rear cover of the unit 4 Only technically qualified service personnel should perform all installation and service These workstations are designed to require no service in the course of normal operation by an operator 26 143095 D Chapter 3 Maintenance The 1506 and 1507 systems are designed to withstand the harsh environment of the factory floor Routine maintenance can help keep your system in good operating condition Preventive maintenance consists of several basic procedures that will greatly reduce the chance of system malfunction Schedule preventive maintenance along with the regular equipment maintenance to minimize down time General Preventive Maintenance Here are some preventive measures you can take Clean or change the fan filter periodically to ensure that the air circulating in the unit is clean Wash the
40. panel of both the 1506 and 1507 Node Boxes 1506 Back Panel and Power Panel Back Panel Power Panel Hard drive access Fan and filter CD ROM drive Floppy drive i Power connector Voltage selector switch and plug retainer under retainer bracket bracket Figure 1 3 1506 Back Panel and Power Panel 5 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction 1507 Back Panel and Power Panel Back Panel Power Panel Hard drive access Fan and filter CD ROM drive Power connector and plug retainer Floppy drive bracket Figure 1 4 1507 Back Panel and Power Panel 6 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction 1506 and 1507 I O Panel The following figure and table outline the features of the I O panel on the 1506 or 1507 Node Box Parallel Port COM Ports Keyboard Port Optional removable CompactFlash access or O optional 9000 XBAY connector port VIDEO USB 19 1007 KEYBD Figure 1 5 1506 I O Panel Table 1 1 1506 and 1507 I O Panel Description The parallel printer port LPT1 is a DB 25 pin female connector This port provides a standard PC compatible printer interface COM1 is RS 232 485 compatible RS 232 is connected to the lower 9 pin stacked DB connector The top part of this stack is the RS 485 version of the same port Since these connectors are attached to the same port only one can be used at
41. puter Systems Chapter 2 Installation Note Electrical equipment cannot be installed in Division 1 locations unless they are intrinsically safe installed inside approved explosion proof enclosures or installed inside approved purged and pressurized enclosures Division 2 Locations Division 2 locations are listed below e Class I volatile flammable liquids or flammable gasses are handled processed or used but confined within closed containers or closed systems from which they can escape only in cases of accidental rupture or breakdown of such enclosures or systems or in case of abnormal operation of equipment e Ignitable concentrations of Class I vapors or gasses are normally prevented by positive mechanical ventilation but which may become hazardous due to mechanical failure of those ventilation systems e Location is adjacent to a Division 1 location e Class II combustible dust is not normally in the air in quantities sufficient to produce explosive or ignitable mixtures Dust accumulations are normally insufficient to interfere with normal operation of electrical equipment or other apparatus Combustible dust may be in suspension in the air as a result of the following malfunctioning of handling or processing equipment combustible dust accumulations on or in the vicinity of electrical equipment may be ignitable by abnormal operation or failure of electrical equipment Groups All electrical equipment that is approv
42. ransformers on the incoming AC power line to the system is always a good practice An isolation transformer is especially desirable in cases in which heavy equipment is likely to introduce noise onto the AC line The isolation transformer can also serve as a step down transformer to reduce the incoming line voltage to a desired level The transformer should have a sufficient power rating units of volt amperes to supply the load adequately Proper grounding is essential to all safe electrical installations Refer to the relevant Federal State Provincial and local electric codes which provide data such as the size and types of conductors color codes and connections necessary for safe grounding of electrical components The code specifies that a grounding path must be permanent no solder continuous and able to safely conduct the ground fault current in the system with minimal impedance minimum wire required is 18 AWG 1 mm Observe the following practices e Separate ground wires P E or Protective Earth from power wires at the point of entry to the enclosure To minimize the ground wire length within the enclosure locate the ground reference point near the point of entry for the plant power supply e All electrical racks or chassis and machine elements should be Earth Grounded in installations where high levels of electrical noise can be expected The rack chassis should be grounded with a ground rod or attached to nearby Earth stru
43. re Installation Instructions for Microsoft Windows NT Workstation 4 0 shipped with systems preinstalled with Windows NT This document is devoted to the reinstallation of your Windows NT Workstation 4 0 operating system and drivers utilizing the Recovery Media provided with your Pro face Xycom industrial computer Note This procedure assumes that the computer hard disk drive has been completely corrupted or replaced Warning This procedure will destroy data that may exist on the hard disk drive 34 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Windows XP Reinstallation If you need to reinstall the Windows XP operating system refer to the Pro face Xycom Workstation Software Installation Instructions for Microsoft Windows XP shipped with systems preinstalled with Windows XP This document is devoted to the reinstallation of your Windows XP operating system and drivers utilizing the XP CD provided with your Pro face Xycom industrial computer If you want to install a new operating system or reinstall a current operating system refer to the Windows XP Professional CD ROM shipped with systems preinstalled with Windows XP Professional Note This procedure assumes that the computer hard disk drive has been completely corrupted or replaced Warning This procedure will destroy data that may exist on the hard disk drive If you want to install a new operating system or rei
44. rove neues ckuceccedeatn cuz chs sue tadestuasnckacecsedentnisecenliaees 39 APPENDIX B AC MODEL BLOCK DIAGRAM 00sssssssessssesssssessssssssssssssssesssssesssssssesssssessssssssssssssesesseeeees 40 APPENDIX C PINOUT O jevecisicseness sonssciciecennsasonsscnaceccussacetssctstecenssncenasecscnscsetacenesetstecesnsacensscsassscsetedebeseasincesnsacencsess 40 KEYBOARD PORT CONNECTOR E a ek se A NA 41 MOUSE PORT CONNECTOR 2 codicia ill dd Seasick cobarde data 41 DUAL USB CONN OTOR USB ocacion id waaasinalteabasnvacassest Ii irradia raid 41 PARALLEL PORT CONNECTOR EPT unica ia ada oi 41 SERIAL PORT CONNECTORS EH india ind andaa aa a ind sado liinda a nda are edad deal 42 COM da ida 42 COM A A dd Ed aen 43 VGA CONNECTOR imhassar ad liliana ladilla lides aa dre adna tame 43 APPENDIX D AIM3 CONTROLLER JUMPER S cooocccoccccnnnononononononononononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn cnn cnn nn cnn nana nn nnnnnnnnnnns 44 APPENDIX E THE RAID ENABLED 1507 IPC OPTION 0 0 ssssssssssssssssssssssssssessssssseesssssssssssssssssssseseseeeees 45 ii 143095 D Chapter 1 Introduction Product Overview The 1506 and 1507 Node Box Industrial PCs offer a powerful compact package for the factory floor and other harsh environments These node box industrial PCs feature an open architecture to meet a wide variety of applications that require both a powerful PC and a durable industrial enclosure The systems integrate a
45. t ate sua toen Ahi tttia 4 BACK PANELS AND POWER PANELG ccccccccccsseeeeeeceeneesseceeccececansnecceseetsaensseceeeeeneaaseseceeessueesseceeseetsuagssecesetensaeaeseceeeteea 5 1506 Back Panel and POWEPr PAN A O ene aa 5 1507 Back Panel and Power PANG iii ccvtievcccvsicseiesdsdessdetedtecoatdeds vente deg aer tA eika adap rea Vadar AA reder stene 6 1506AND 1507 1 0 PANE AFE TTEA AEA A 7 UNPACKING THE SYSTEM n n n a eh EE ees odes a Se SL PEE E 8 QUICK STARTUP cc Loi tt cath G dre detente td tt chloe wines db dba kd has deta 9 CHAPTER 2 INSTALLAT ON ici cent Er ll 10 INSTALLATION OVERVIEW a ea Aaa i n 10 SYSTEM MOUNTING DIMENSIONS codos aen ga dolosa rodri oirlo a Na NE A NaN 12 1506 MOUNTING DIMENSIONS cia A Ai ai aaae Di izo 12 1507 MOUNIND DIMENSION Si A a Sera nneea Arie E E RETN 14 POWER MANAGEMEN Tosasnctiano cacon darla ici daa NEN anauseugdeacainauncsaueslvaiedan ueausdaltaauctusunsszaanmeanslupusanreaseresede 16 System POWER A AT 16 1506 POWEr SUDDIV eiii NEE AE ERE R RETTE ELT AIDA DAA 16 1507 Power SUDPIV ss A aio 17 EXCESSIVE CAE 23 dots odie ata aiii ar he in dd da iia ida e iaa iia 17 EIGCIICALNOISG tii A a e tod Maes basta Dad 17 Line Voltage VAN abeto 18 AG POWER CABLE o e e e o a o e ice tes ad 18 INSTALLING INTERNAL HARDWARE OPTIONS coocccccccncncnnncncnnncnnnnnnononononononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonononononenaninans 20 DRAM and Additional DRAM Dual Inline Memory Modules DIMMS o
46. t chassis to the enclosure chassis can be established using the 6 32 threaded ground point hole provided on the bottom panel of the unit 6 Turn on power to the system The system will boot up the installed operating system 7 Install the application software via a floppy drive CD ROM or the network Additional aspects to take into account when mounting your 1506 and 1507 Node Boxes Consider locations of accessories such as AC power outlets and lighting interior lighting and windows for installation and maintenance convenience Prevent condensation by installing a thermostat controlled heater or air conditioner To allow for maximum cooling avoid obstructing the airflow Place any fans or blowers close to the heat generating devices If using a fan make sure that outside air is not brought into the enclosure unless a fabric or other reliable filter is used This filtration prevents conductive particles and other harmful contaminants from entering the enclosure Do not select a location near equipment that generates excessive electromagnetic interference EMI or radio frequency interface RFI Examples of these types of equipment are high power welding machines induction heating equipment and large motor starters Place incoming power line devices such as isolation or constant voltage transformers local power disconnects and surge suppressers away from the system The proper location of incoming line devices keeps power
47. te storage media h ee Note This feature cannot be used if the removable CompactFlash optional option was not ordered 9000 XBAY The 9000 XBAY connector port is a factory installed option that provides a connector port connection from the 1506 1507 to any two IDE devices used by the optional optional 9000 XBAY Note This feature cannot be used if the 9000 XBAY option was not ordered This port can be used for the removable CompactFlash or the external bay connector but notboth If the user chooses one of these options it must be factory installed Unpacking the System When you remove the system from its shipping container verify that you have the parts listed below Save the box and inner wrapping in the event you need to reship the unit e 1506 or 1507 unit e Documentation kit which includes e Power connector e Fourteen 10 32 hex nuts 2 spares e Cable clamp and screw for strain relief of power cord e Documentation and Support Library CD ROM e Operating System Recovery Media or retail operating system CD ROM e Mounting hardware 8 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 1 Introduction Quick Startup This section gives you the steps to get the system up and running without explaining the capabilities and options Warning Remove power from the unit and disconnect the power cord before making any adjustments to the inside or outside of the computer Warni
48. tts Excessive Heat The units withstand temperatures from 0 to 50 C and are fan cooled To keep the temperature in range the cooling air at the base of the system must not exceed 50 C Allocate proper spacing between internal components installed in the enclosure Units with standard BIOS release 1 3 or greater will automatically throttle down the CPU speed if the temperature exceeds the maximum allowed CPU temperature Electrical Noise Electrical noise is seldom responsible for damaging components unless extremely high energy or high voltage levels are present However noise can cause temporary malfunctions which can result in hazardous machine operation in certain applications Noise may be present only at certain times may appear at widespread intervals or in some cases may exist continuously Noise commonly enters through input output and power supply lines and may also be coupled through the capacitance between these lines and noise signal carrier lines This usually results from the presence of high voltage or long close spaced conductors When control lines are closely spaced with lines carrying large currents the coupling of magnetic fields can also occur Use shielded cables to 17 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation help minimize noise Potential noise generators include switching components relays solenoids motors and motor starters Refer to the rele
49. un the test insert the diagnostics disk into drive A Turn on the computer the diagnostics program will boot up Figure 4 2 shows the Main Menu Copyright xxxx lt Company Name gt All rights reserved Diagnostic Tests Sequence Selection Menu Rel xx WILL pause on error Auto select tests Save setup to file Quit and exit to DOS 5 SINGLE PASS test mode 6 Deselect all tests 7 8 Extract setup from a file Return to previous screen RAM Test Video Interface Test Video RAM Test Speaker Port Test tended RAM Test LPT1 Printer Port 17 Time Clock Test LPT2 Printer Port 1 Serial Port Test Hard Drive Interf 7 Serial Port est E Hard Drive Interface 1 Serial Por est Floppy Drive Interfac Serial Por est Floppy Drive Interfac Coprocesso est Keyboard Keypad Tests Video Adjustments Test Test Selected ENTER START TESTING Use the letters to move the cursor and select deselect or use the arrow keys to move then use th SPACE key to select deselect a test or function Figure 4 2 Main Menu Note Please read the DIAG TXT file on the diagnostics disk for detailed information about the tests Note Avoid repeated running of any hard disk diagnostic utility if you use the Solid State Flash drive option The Flash drive has a limited number of writes to each logical sector Repeated writes from a diagn
50. vant Federal State Provincial and local electric codes which provide data such as the size and types of conductors color codes and connections necessary for safe grounding of electrical components It is recommended that the high voltage and low voltage cabling be separated and dressed apart In particular the AC cables and switch wiring should not be in the same conduit with all communication cables Line Voltage Variation The unit s power supply is built to operate with input voltage ranges of 100 132 200 240 VAC 1506 or 100 240 VAC 1507 while still allowing the system to function within its operating margin As long as the incoming voltage is adequate the power supply provides all the logic voltages necessary to support the processor memory and I O In cases in which the installation is subject to unusual AC line variations use a constant voltage transformer to prevent the system from shutting down too often However a first step toward the solution of the line variations is to correct any possible feed problem in the distribution system If this correction does not solve the problem use a constant voltage transformer The constant voltage transformer stabilizes the input voltage to the 1506 and 1507 units by compensating for voltage changes at the primary in order to maintain a steady voltage at the secondary When using a constant voltage transformer check that the power rating is sufficient to supply the unit AC Power
51. wire runs as short as possible and minimizes electrical noise transmitted to the unit Make sure the location does not exceed the unit s shock vibration and temperature specifications Install the unit in the rack or panel in such a way as to ensure that it does not cause a hazard from uneven mechanical loading Incorporate a readily accessible disconnect device in the fixed wiring on permanently connected equipment Avoid circuit overloading of the supply circuit 11 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation System Mounting Dimensions This section contains the mounting dimensions for the 1506 and 1507 Node Boxes 1506 Mounting Dimensions Figure 2 1 shows the vertical mounting dimensions for the 1506 Node Box Figure 2 2 shows the horizontal mounting dimensions for the 1507 Node Box gt 1778 pe eS 4x 0 20 4x 5 1 2x 1 97 ad 2x 177 8 8x 0 20 8x 5 1 2x 50 0 2x 7 00 8x 0 40 8x 10 2 0 40 10 2 ge 2x 177 8 3 76 95 5 5 48 6 91 139 2 175 5 6 11 155 2 2x 243 8 2x 9 60 12 87 326 9 All dimensions in inches mm Figure 2 1 1506 Vertical Mounting Dimensions with mounting rails attached 12 143095 D 1506 1507 Industrial PC AT Computer Systems Chapter 2 Installation 2x 2 47 2x 62 7 1 2x 0 50 2x 12 7 0 40 TYP 2x 0 50 2x 12 7 10 2 E 2x 7 00 2 177 8 4x0 20 4x5 1 bx 1 17 2x 7 00 2x 177 8 8x 0 20 Bx 5 1 2x 29 2x 7 00 2x
52. ystem will be partially filled by the 640 x 400 resolution of this particular mode The expansion function uses lower resolutions that will better utilize the display by stretching the information in an attempt to fill the display Operating systems such as Microsoft Windows 98 and Windows NT use display drivers to handle the different flat panel displays Here expansion is not necessary since there is a specific driver for each resolution display Expansion does not add any resolution to the existing information it simply stretches the information to better fit the display Text and graphic screens can look somewhat grainy from the process of expansion Miscellaneous Drivers Refer to your operating system and peripheral manuals for information on installing drivers related to these items Note If you ordered a system with Windows pre loaded you may have to purchase and install an external parallel port CD ROM drive or order your system with a CD ROM drive pre installed to be able to install Windows drivers The Windows operating system ships only on CD ROM Note For further assistance contact Pro face Technical Support at 734 944 0482 or support profaceamerica com 36 143095 D Appendix A Technical Specifications Hardware Specifications Table A 1 lists the hardware specifications for the 1506 and 1507 Industrial Node Box systems Table A 1 Hardware Specificati

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