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1546 and 1547 - Pro

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1. 340 288 0 PEAR 177 81 247 62 81 ex 7 000 177 81 ex 7 000 177 81 200 5 1 be 4x 500 112 71 8x 8200 9511 400 11021 ee 2 400 101021 1 400 10 23 zs ER T E 1 9 920 252 01 10 72 272 3 9 24 234 71 65 b e JH 2 70 6 H SS 7 2 1 C75 cO 2 7 2X 960 243 8 1138 12892 2 70 322 5 All dimensions in inches mm Figure 2 2 1546 Horizontal Mounting Dimensions 13 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation 1547 Mounting Dimensions Figure 2 3 shows the vertical mounting dimensions for the 1547 Node Box Figure 2 4 shows the horizontal mounting dimension for the 1547 Node Box 2x 11 40 289 6 j 11 40 6 11 40 289 6 x 0 00 12511 8x 20 125 11 8 40 1910 21 8x 50 18 717 8x 40 HS C 4 60 1116 81 Rp 548 1391 696 176 71 6 32 160 5 p er ex 116 29 5 16 16 410 5 i 1717 436 11
2. D serie s beer D An Ad e ppm Ad De ei p lel A Ee med LA Dr ela al 21 DEFINITIONS MM 23 GE AANEoe Wo E M 23 GLASS Il EOGRT IONS ec coo erecto oak ee tbe tete oe A ee Mil De 23 DIVISION 1 Eaa GE ONE E E E 23 DIVISION 2 EOCATIONS A N E E EN E A E E A E 24 GROUPS nra prr 24 ENCLOSURES a E A E E A E E A E 24 POWERS WITCH E E HMM ENE 25 GABEE GONNEGTIONS 5 2 2 24 T ATE 25 GOMMUNIGATION GABLE INTERFACE nn A Ed E nt 25 OPERATION AND MAINTENANCE eese caso bends eee oda eie deu eu 26 CHAPTERS MAINTENANGE iaaa aa c a aiara aa aaa aa a aa aaa aia adan OP aandaa iaia narada Adana 27 GENERAL PREVENTIVE MAINTE ANCE 27 Fuse Replacentent neun E TO E Se A eaten 27 Fan Filter Replacement 27 RECOMMENDED HARD DRIVE PREVENTIVE 28 SYSTEMIBATTERY REPLACEMENT cbs Madea 29 PRODUCT REPAIR
3. 45 Serial ports since uires 7 System mialntenance nie 26 Operatlon i ee D GERI IUe 26 System components Front panelz ipee 3 System Power eene 16 connector iiri nile 47 Video drivers eese 38 Video expansion 38 Video pott iei 8 144771 B 1546 1547 Industrial PC AT Computer Systems End 144771 B Xycom Automation L L C Canada Sales 905 607 3400 Pro face 734 429 4971 Northern Europe Sales 44 1604 790 767 Fax 734 429 1010 Southern Europe Sales 39 01 1 770 53 11 144771 B http www profaceamerica com
4. 50 COMM CONFIGURATION JUMPER 51 P2 RS 422 485 TERMINATOR CONFIGURATION 51 P2 COMM EXTERNAL VOLTAGE SELECT n tb Ere pet ev he ge tb Ere D E E CE D 51 P2 COMM 1 RS 485 TRANSMIT GATING OPTIONS ccccccccccccccccccccecececucecececucececccucucecseucuceceeuaucucusecueusueueueueueuausuauanads 51 EXTERNAL RESET FNAB E COMM Ors ree tede e te exe prego 51 ji 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction Chapter 1 Introduction Product Overview The 1546 and 1547 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 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 Standard Features The 1546 and 1547 units come standard with the following features AIMA board Wall or shelf mountable Flash BIOS SATA HD contr
5. oki mute det teh eterna 29 general antedios niet tede ds 27 hard drive iine Le ME 28 Mouse port eene 8 43 Noise electrical 17 Operating systems Installations cene cbe 37 Parallel port connector 44 PC AT installation and PCI boards 20 Pinouts COMI dcos S Lack uai ar 45 46 47 Dual USB connector 44 keyboard 43 mouse corinector 2 43 parallel pott 2 treten 44 VGA connector 47 Ports 144771 B 1546 1547 Industrial PC AT Computer Systems COM itai directe its 7 keyboard Pha 7 43 Mo EE 8 43 erleei e nem 7 44 printer ian eit ee 7 Serial iecit nen delle 7 c a i dette net ea eek 8 Power tete rein 16 Power supply eene 16 Power switch eere 25 Preparing the system 10 Preventive maintenance 27 battery oie Om 29 general eR eR RR 27 h rd dive s 28 Printer port 7 53 End Product repair program 33 Returning the 33 Safety agency approval 22 Serial port connectors
6. Figure 1 5 1546 Panel Table 1 1 1546 and 1547 Panel Feature Description Parallel Port The parallel printer port LPT1 is a DB 25 pin female connector This port provides a standard PC compatible printer interface COM Ports Four serial COM ports with three external ports configured as RS 232 and one configurable as either RS 232 or RS 422 or RS 485 The fourth port is an internal header only and defaulted as disabled For more information see jumper details in Appendix D Keyboard Port 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 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction Feature Mouse Port Video Port USB Ethernet Ports Table 1 1 1546 and 1547 Panel Description 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 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 acti
7. toe ee ee eet p eee e ore Ue e eade Lege ree e dod 41 APPENDIX B AC MODEL BLOCK DIAGRAM c ecce ccena rara rara rrr rr rara 42 APPENDIX C PINOUT 43 KEYBOARD PORT sialic estes cose Eee co i o desi al e dte fte eO e see P eed 43 MOUSE PORT CONNEGTORA ak a etude ee E d ties e UP Eoi i dein 43 FORU SB CONN OTOR USB rss RU eia eue 44 PARALLEL PORT CONNECTOR LP TH eiecit toco eiecti veta orate oe 44 SERIADPORT GONNEGTORS 1 2 epe ees eame ce ee ecco Se mde a aaa a Eoo cese ceat e de setae eee bet bee vedere 45 eee 45 COM TE 46 C 46 eo 47 M NC E 47 APPENDIX D AIM4 CONTROLLER ener nenne nenne nara r nra 48 G EAR GMOS SETTINGS tut A a e oed t RE see ide A tee ecce 48 6 E x L L cM CR ILE IN 48 IGD POWER erre Tee Ue E c core Ae ecc M 48 LGD eeu estende se ee me edere S e cde oe Ue e e n eco e ED Te retenta 48 N
8. IDE Mode 49 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix D AlM4 Jumper Settings IDEI Connector Master Slave Mode JP19 IDE Master Slave Select 1 2 Master 2 3 Slave Note Affective only when drive is physically jumpered for Cable Select J5 Connector CDROM Master Slave Mode JP20 CDROM Master Slave Select 1 2 Master 2 3 Slave Note 1 1 2 Slave 2 3 Master Note 2 Note 1 Affective only when CDROM is programmed for Cable Select Mode 2 Affective only when CDROM is programmed for Reverse Cable Select Mode IDE1 Connector Voltage Select JP21 IDE1 Voltage Select 1 2 Compact Flash Mode 3 3VDC 2 3 HDD etc 5VDC Comm Port Settings P2 Comm 1 Connector Mode Configuration Jumper RS 232 Mode RS 422 Mode RS 485 Mode JP2A 1 2 2 3 2 3 JP2B 1 2 2 3 2 3 JP2C 1 2 2 3 2 3 JP2D 1 2 2 3 2 3 JP2E 1 2 2 3 2 3 JP2F 1 2 2 3 2 3 JP2G 1 2 2 3 2 3 JP2H 1 2 2 3 2 3 50 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix D AlM4 Jumper Settings Comm Configuration Jumper JP8 Comm 1 Communication Mode 1 2 RS 485 2 3 RS 422 P2 RS 422 485 Terminator Configuration Jumper RS 422 Mode RS 485 Mode Terminator Terminator Terminator Terminator Out In Out In JP5 2 3 1 2 2 3 1 2 JP7 2 3 1 2 Note 1
9. 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 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance Chapter 3 Maintenance The 1546 and 1547 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 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 1 if the area is dusty you should schedule maintenance more often than if it 15 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 ca
10. 43 tet 43 senal port e Gaels 45 Definitions class and 23 DIMM iere em Lee Ree 20 Division 1 locations 23 Division 2 locations 24 Documentation kit sees 8 DRAM eene 20 Drivers iristallitig s rrt ERR 38 39 Mlle M 38 Dual Inline Memory Modules 20 Enclosures eene 25 uM En 27 filter replacement ssse 27 Features Standard edet ene 1 52 End Front panel eese 3 Fuse replacement sense 27 CIIM 24 Heat excessive 17 Installation DRAM utet Redes 20 PET 38 hazardous 21 internal hardware 20 operating 37 PC AT and PCI 20 Jumper settings AIM4 CPU 48 Keyboard idet ee iens 43 Keyboard port eee 7 Line voltage variation 18 Maintenance eene 27
11. 7 COM3 Connector Pinout Pin Description Pin Description 1 CHASSIS GND 14 NC 2 TXD3 15 NC 3 RXD3 16 NC 4 RTS3 17 NC 5 CTS3 18 NC 6 DSR3 19 NC 7 GND 20 DTR3 8 DCD3 21 NC 9 NC 22 10 NC 23 NC 11 PB 24 NC 12 NC 25 NC 13 NC Note The P1 connector contains a remote system reset option The reset jumper JP1 shall be in position 1 2 in order to activate the Reset function The PB RESET pin shall be switched to GND to reset the entire board 46 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix C Pinouts 4 The following table lists the signal definitions for the 4 DB 9 connector Table C 8 4 Connector Pinout Pin Signal DCD4 0564 RXD4 RTS4 TXD4 CTS4 DTR4 GND NC N al A 4 e Note COM4 to be employed when using a UPS type power supply containing RS 232 monitoring capability Connector The following table lists the signal definitions for the VGA DB 15 connector Table C 9 VGA Connector Pinout Pin Signa 9 FusedVCC s omo s l 47 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix D AlM4 Jumper Settings APPENDIX D AIM4 CONTROLLER JUMPERS The following tables show the position and function of the controller jumpers Not
12. All dimensions in inches mm Figure 2 3 1547 Vertical Mounting Dimensions 14 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation 2X 11 400 289 6 e 2X 11400 289 61 81 at 7 E _ _ _ NEG T 9 L 7 20 195 1 1 8X 620 65 11 8 40 181021 1 e 10 620 269 71 9 240 234 71 9 2 9 980 253 51 e e 69 B HODI 2 62 66 61 e e i ERE ex 87 22 2 2X 14 00 355 61 15 98 406 01 1095 27 8 All dimensions in inches mm Figure 2 4 1547 Horizontal Mounting Dimensions 15 144771 B 1546 1547 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 1546 and 1547 Node Boxes System Power Using isolation transformers 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 lin
13. E THERE DU PROP MEDI EEUU EE UD AER EE 2 MOUNTING PLATES eaa ec da vee sien ae corvo ce oa e rv ec Vv YE Ve EY Vae cae WE VER EY a E EE edis 3 1546 Mounting Plale 1 eon ebbe oer 3 1547 e hee i p e 4 BACK PANELS AND POWER 5 5 1546 Back Panel and Power Panel eei exact sao dee aera id opo su sina qa ka Dona a daa eda a aga pora V ka a ha 5 1547 Back Panel and Power PANEL ist iet ed de een a ek ave edades aea Toda o dd dE co pibe en rd deer 6 1546 AND 1547 I O BANEE inediti AE A 7 UNPACKING THE SYSTEM age ees ee edocet SUEDE code etse Ue do EE Eee E e Le ee el 8 QUICK STARTUP 9 CHAPTER 2 NSTALLATI N 2 sape a ota copa aen crc opaco rara DEED OR SIR 10 INSTALLATION OVERVIEW D E E DEL E ce DE D DRE EE DEVE HE 10 SYSTEM MOUNTING DIMENSIONS 2 45 25 De ub octo cotes oce dee esce DVD ITO 12 1546 Mounting Dimensions sessi nennen n
14. 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 39 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix A Technical Specifications Appendix A Technical Specifications Hardware Specifications Characteristic V Mount Size H Mount Size Size Weight Electrical AC Power Supply Passive Backplane Available Power for expansion by user Agency Approvals Regulatory Compliance Table A 1 lists the hardware specifications for the 1546 and 1547 Table A 1 Hardware Specifications Specification 1546 1547 12 79 x 10 72 x 6 00 17 17 x 10 62 x 6 00 12 79 x 6 91 x 9 50 17 17 x 6 96 x 9 50 12 79 x 9 24x5 74 17 17 x 9 24 x 5 74 14 6lbs 19 6 100 240 VAC 50 60 Hz 74 Watts Maximum i e 1Amp 250 watts 250 watts Four available expansion slots Four available expansion slots one Y2 length PCI one Y2 length PCI two 34 length PCI two full length PCI one length PCI or ISA one full length PCI or ISA 3 3 V 4 0
15. Note 1 Note 1 Jumper not used Insert in factory default position P2 Comm 1 External Voltage Select JP3 Output Voltage at P2 Pin 9 1 2 5VDC Output 2 3 12VDC Output Note Either 5VDC or 12VDC will appear on P2 Pin 9 when jumpered for RS 422 or RS 485 P2 Comm 1 RS 485 Transmit Gating Options Transmit Enable JP4 JP6 DTR Active 1 2 3 4 DTR Inactive 1 2 1 2 RTS Active 2 3 3 4 RTS Inactive 2 3 1 2 Auto Turn Around Note 1 5 6 Note 1 Jumper not used Insert in factory default position External Reset Enable Comm 3 JP12 Description 1 2 External AIM4 Reset Active 2 3 Normal Operation 51 144771 B 1546 1547 Industrial PC AT Computer Systems Index AIMA JUlmipers x ettet epo terree 48 29 Cable communication cable interface 25 9 e Baits 25 Class locations sees 23 Class Il locations 23 COM ports cerei tins 7 COM connector eee 45 Connectors AIM4 COMI a hii icti meets 45 parallel 44 iube 47 44 tette tn
16. and 1547 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 no responsibility for installations of this equipment or any devices attached to this equipment in Division 1 locations Note When additional cards are added it is the customer s responsibility to ensure that the cards chosen meet operating conditions for Class and ll 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
17. 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 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 bot
18. 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 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance System Battery Replacement The 1547 1547 AIM4 CPU board includes a coin cell type lithium battery that maintains computer configuration date and time information when input power is removed from the system If the AIM4 CPU board battery life is ended then the 1546 1547 computer will no longer maintain the configuration information date or time and the battery will need to be replaced In this case the following types of error messages will be displayed on the screen at start up time ERROR 0271 Check Date and Time Settings Warning 0251 System CMOS Checksum Bad Default Configuration Used Press Fl to Resume F2 to Setup BATTERY SPECIFICATIONS Part Number CR2032 Voltage 3V Nominal Capacity 220 mAh This battery must be a UL Recognized component BATTERY LIFETIME Battery current is not consumed while in
19. 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 Because of repair maintenance conditions leakage or mechanical failure 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 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 23 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation Division 2 Locations Groups Enclosures Division 2 locations are listed below 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 ca
20. mouse controller 2 Remove the top cover of the rear chassis 1546 four 6 screws 1547 five 6 screws 3 Locate the battery holder and remove the coin cell battery 30 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance 4 Immediately apply electrical tape to the old battery on all sides in order to prevent shorting the battery The battery may still have charge and a short may cause fire or explosion Do not dispose of the battery with standard waste Contact your local waste disposal agency for the address of the nearest battery deposit site 5 Install the new battery as indicated below Note position of sign TO RE ASSEMBLE THE 1546 1547 COMPUTER 1 Install the rear chassis top cover 1546 four 6 screws 1547 five 6 screws TO SETUP THE CMOS MEMORY 1 Pluga QWERTY keyboard into the Keyboard port on the side of the 1546 1547 computer 2 Apply power to the 1546 1547 computer The same ERROR and WARNING messages should appear as before battery replacement This is because the CMOS memory must be setup ERROR 0271 Check Date and Time Settings Warning 0251 System CMOS Checksum Bad Default Configuration Used Press Fl to Resume F2 to Setup 3 Press the QWERTY keyboard F2 function key to enter CMOS Memory SETUP 81 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance 4 The SYSTEM TIME and SYSTEM DATE fields are located at the top
21. 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 Underwriters Laboratories Inc UL 1604 Standard for Safety Electrical equipment for use in Class I and Class II Division 2 and Class III hazardous classified locations UL Listed File E180970 Underwriters Laboratories Inc UL 508 Industrial Control Equipment UL Listed File E107636 21 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation Canadian Standard Association Specification C22 2 No 213 1967 Non incendiary electrical equipment for use in Class I Division 2 Hazardous Locations cUL Listed File E180970 Canadian Standards Association Specification C22 2 No 142 cUL Listed File E107636 Warning Suitable for use in Class 1 Division 2 Groups B C and D hazardous locations or non hazardous locations only Warning Explosion Hazard Substitu
22. 0 maximum 3 3V 4 00 maximum 5V 400A maximum 5V 4 00 maximum 5V 160mA maximum 5V 160mA maximum 12V 3 00 maximum 12V 3 00 maximum 12V 240mA maximum 12V 240 maximum UL 508 Listed UL 1604 Listed cUL CSA C222 No 142 Listed cUL CSA C222 No 213 Listed FCC 47 CFR Part 15 Class A CE EMI EN55022 Class A IMMUNITY EN61000 6 2 SAFETY EN60950 HARMONICS EN61000 3 2 Class A FLICKER EN61000 3 3 40 144771 A 1546 1547 Industrial PC AT Computer Systems Appendix A Technical Specifications Environmental Specifications Table A 2 lists the environmental specifications for the 1546 and 1547 Table A 2 Environmental Specifications Characteristic Temperature Operating Non operating Humidity Operating Non operating Altitude Operating Non operating Vibration 5 to 2000 Hz Operating Non operating Shock Operating Non operating Specification 0 to 50 C 32 to 122 F 20 to 60 C 4 to 140 20 to 80 RH non condensing 20 to 80 RH non condensing Sea level to 10 000 feet 3 048 m Sea level to 40 000 feet 12 192 m 0 006 0 15mm peak to peak displacement 1 0g maximum acceleration 0 015 0 38mm peak to peak displacement 2 5g maximum acceleration 159 peak acceleration 11 msec duration 5 sine wave 30g peak acceleration 11 msec duration 5 sine wave Consistent with internal component specifications The
23. 1546 1547 ee Se es Industrial PC AT Node Box Systems User Manual 2007 XYCOM AUTOMATION L L C Printed in the United States of America 1546 1547 Industrial PC AT Computer Systems Revision Record Revision Description Date A Manual Released 8 06 B Name change correct where applicable with document 4 07 Part Number 144771 B 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 Compliance Statement NOTE This equipment has been tested and found to comply wit
24. 2000 operating system are also available If you need to reinstall an 36 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 4 Troubleshooting 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 2000 or Windows XP Professional operating system you must have an internal CD ROM drive or an external parallel port CD ROM drive A floppy drive may also be required for loading drives when F6 is pressed during install Windows 2K and Windows XP ship only on CD ROM 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 XP Reinstallation If you need to reinstall the Windows XP operating system refer to the Pro face Xycom Workstation Software Installation Instructions For Microsoft Wind
25. 33 CHAPTER 4 1 5 34 DIAGNOSTIC TESTINGSM abu B Mp LM UAM ID DUM IDA ADI RN M E E 34 Create Diagrnostie Disk E bo A EH UE eL ee Ee pH eid 34 Prepare the System vno edu elec petet eed uie eer eO Pe aee eire dede persto a4 34 FRRUNNING THE AL ESTS4i E E E E E 36 i 144771 A 1546 1547 Industrial PC AT Computer Systems Table of Contents REINSTALLING OPERATING SYSTEMS dede pete cda Cre dee sese edere ed aN EN 36 Windows 2000 Reihstallation P RUE E ten 37 Windows s de erdt s tmn cente 37 INSTALLING DRIVERS s 38 EEUU 38 Video EXPANSION ss oie ye e me ot eed E eere dne 38 Miscellaheous DriVers s oio tree A P td eos ed ied te A pred ed tete er ee p rp EUER 39 APPENDIX A TECHNICAL SPECIFICATIONS Lecce cec scene nnn nnn arr rr rr 40 HARDWARE SPEGIFICATIONS cech Ii dc n NI Kore c Mei eani eae cr 40 ENVIRONMENTAL SPECIFICATIONS
26. 546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction Back Panels and Power Panels The following figures show the back panel and power panel of both the 1546 and 1547 Node Boxes 1546 Back Panel and Power Panel Back Panel Power Panel Fan and filter access CD ROM drive Floppy drive Removable Compact Flash Power connector and plug retainer bracket Figure 1 3 1546 Back Panel and Power Panel 5 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction 1547 Back Panel and Power Panel Back Panel Power Panel Hard drive access Fan and filter CD ROM drive Power connector and plug retainer bracket Removable Compact Flash CF access Figure 1 4 1547 Back Panel and Power Panel 6 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction 1546 and 1547 I O Panel The following figure and table outline the features of the I O panel on the 1546 or 1547 Node Box PNP T S NUES EON fF Se NS ON LP
27. OTE ONLY SPECIFIC LCD PANELS SUPPORT THESE FEATURES eene nnn rri i 49 NORMAL REVERSE SCAN 49 NOTE ONLY SPECIFIC LCD PANELS SUPPORT THESE 49 e PH RESOLUTION RE IE octet da stead 49 CRIMEC DiSELE GT ese aa cs eee eee soa ees sce da ee eed eed dad eve 49 SATA Mode 5 amp 49 IDET CONNECTOR MASTER SEAVE MODE ena EE Dave 50 J5 CONNECTOR CDROM MASTER SLAVE MODE nene nene nnne nn s n 50 IDET CGONNECTOR VOLTAGE ceste ceret e ce eee eee ce EI OE E De DE EAE E eT EYE CER DEED EHE Eee ES 50 P2 COMM 1 CONNECTOR MODE
28. e Indicates factory default position Clear CMOS Settings JP1 Description 1 2 Normal Operation 2 3 Clear CMOS Settings CPU Voltage Select JP22 Voltage Select CPU 1 2 1 8V 400MHz FSB 1 3Ghz Celeron M 2 3 1 5V 583MHz FSB 2 0Ghz Pentium M LCD Setup Settings LCD Power Select LCD Panel JP9 LCD Voltage 12 1 AU Optronics 1 2 3 3VDC 15 AU Optronics 1 2 3 3VDC Node Box Configuration 1 2 3 3VDC Note 5VD operation is available when 9 is in position 2 3 LCD Mode Selection Operating Mode JP10 2 8 6 Bit Compatibility 1 2 8 Bit Compatibility 48 144771 A 1546 1547 Industrial PC AT Computer Systems Appendix D AlM4 Jumper Settings Note Only specific LCD panels support these features Normal Reverse Scan Select JP11 Scan Mode 2 3 Normal Scan 1 2 Reverse Scan Note Only specific LCD panels support these features LCD Resolution JP13 JP14 JP15 JP16 Display Size LCD Resolution 1 2 1 2 2 3 2 3 15 1024 X 768 1 2 1 2 2 3 1 2 17 1280 X 1024 1 2 1 2 1 2 2 3 12 800 600 1 2 1 2 1 2 1 2 19 1600 X 1200 1 2 1 2 1 2 2 3 Node Box Operation CRT LCD Select JP17 Display Select 1 2 CRT amp LCD 2 3 CRT Only Node Box Configuration HDD CDROM Settings SATA Mode Select JP18 HDD Mode 1 2 Reserved 2 3
29. e 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 Extended RAM Test LPT1 Printer Port Test Time Clock Test LPT2 Printer Port Test Serial Por est Hard Drive Interface 1 Serial Por est 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 diagnostic utility will prematurely shorten the life of the drive Reinstalling Operating Systems The 1546 and 1547 systems ship with Windows XP Professional The Windows
30. e 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 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation Chapter 2 Installation This chapter offers detailed installation instructions and outlines the options for the 1546 and 1547 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 1546 and 1547 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 such 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 enclos
31. e suitable for Class ll installations Class includes Groups A B C and D Class includes Groups and G 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 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 24 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation Power Switch codes and regulations that apply to their specific location Reference NFPA 70 Article 500 for specific regulations in the United States The 1546 and 1547 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
32. e 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 structure 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 gro
33. ed wire This will keep the wire from fraying 18 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation 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 1546 1547 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 cable 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 Oncethe 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 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 In
34. es to the temporary folder you just created 4 Copy the extracted files onto the DOS bootable diskette This diskette will be inserted directly into the unit s floppy drive Prepare the System Before starting the system tests perform the following steps 1 Place the CPU board jumpers and switches to the factory set positions Refer to Appendix for details 2 Plug female end of the AC power cable into the side of the unit and the male end into a properly grounded outlet 3 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 4 Default the CMOS setup to the factory settings After completing all of the preceding steps the unit is ready for diagnostic testing Follow the directions in the Running the Tests section of this chapter 34 144771 1546 1547 Industrial PC AT Computer Systems Chapter 4 Troubleshooting 1 4 4 5e Com 1 RS 232 Serial Loopback Connections Com 2 RS 232 Serial Loopback Connections Figure 4 1 Serial Loopback Connections 35 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Running the Tests To run 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 Company Nam
35. essary to read this section if you are a Windows or OS 2 user and do not plan to run DOS applications 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 system 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 XP and Windows 2K 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 38 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 4 Troubleshooting 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
36. h sides 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 25 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation 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 Hazardous Location installations always observe the following rules 1 Always install the 1546 or 1547 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 15 known to be non hazardous This includes the installation or removal of power cables communication cables or removal of the
37. h 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 Communication cable connectors must be metal ideally zinc die cast backshell types and prov
38. ide 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 144771 B 1546 1547 Industrial PC AT Computer Systems Table of Contents Table of Contents CHAPTER 1 INTRODUCTION 2 Copa rap c a aD 1 1 Standard Feature S 1 Optional Features e
39. le shows the signal definitions for the DB 25 Parallel port connector Table C 4 Parallel Connector Pinout 11 PBUSY 13 SELECT LN 3 35 44 Pm Spa 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix C Pinouts Serial Port Connectors RS 232 RS 422 and RS 485 are supported AIM4 COMI The following table lists the signal definitions for the COMI DB 9 connector Table C 5 COM1 Connector Pinout RS 232 RS 422 RS 485 Pin Signal Pin Signal Pin Signal 1 DCD1 1 TXD note 1 1 note 1 2 RXD1 2 TXD note 1 2 note 1 3 TXD1 3 NC 3 NC 4 DTR1 4 NC 4 NC 5 GND 5 GND 5 GND 6 DSR1 6 RXD 6 NC 7 RTS1 7 RXD 7 NC 8 CTS1 8 NC 8 NC 9 9 Voltage note 2 9 Voltage note 2 Note 1500 termination resistors can be connected across transmit or receive lines by inserting jumpers JP5 and JP7 Refer to Appendix D 45 144771 B 1546 1547 Industrial PC AT Computer Systems COM2 Appendix C Pinouts The following table lists the signal definitions for the COM2 DB 9 connector Table C 6 COM2 Connector Pinout COM3 Pin Signal DCD2 RXD2 TXD2 DTR2 GND DSR2 RTS2 CTS2 N al A RI2 The following table lists the signal definitions for the COM3 DB 25 connector Table C
40. nd G Optional Features Following are optional available features of the 1546 and 1547 Higher capacity SATA hard drives and solid state drives Various CD DVD drive options Internal rear access floppy Various processor speeds Preinstalled Windows 2000 or Windows XP Professional External 9000 USBF USB floppy requires Windows 2000 or XP CompactFlash options up to 4GB 2 5 Dual hard drives 2 5 RAID array support 24VDC power supply on 1547 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 1546 and 1547 Node Boxes 2 144771 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction Mounting Plates The following figures illustrated the mounting plates for the 1546 and 1547 systems 1546 Mounting Plate The 1546 mounting plate protects the system s interior when the system is properly mounted Figure 1 1 1546 Mounting Plate I O Panel Mounting Plate 3 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction 1547 Mounting Plate The 1547 mounting plate protects the system s interior when the system is properly mounted Mounting Plate Panel Figure 1 2 1547 Mounting Plate 4 144771 B 1
41. nne nennen tnnt nennt sent nn nhe nnns nannten 12 1547 Mounting Dimensions eie tet tipa MH RAM ER ESSEN EX sire Ee Pap deeds 14 POWER MANAGEMENT vedere vare rc ea tL save ole ot Er e eve LEE e adv TUR Fev eo e ED v rav a v E EV ve y Fe E a PT Eo Cu 16 System PoWet dU o ire a de euge rr E UP p e an tr ees ears 16 1546 Power Supply tid en cia ha aan e dap i ey cdit ede dta detto eB Rati 16 1547 Power Supply 5 iude D e t dien ai de i ot o dob E die dde 17 Excessive Heat tes a caw Tine smesso Masse eS ees 17 Electrical Noise nhanh nnn nns se saa inns siis sana a isset esses saa senes sess asas rese etas sana an 17 Line Voltage Varlatloh coenobio Enero EE OT ee EDU edad 18 AC Power Cable et ee re ES esten eet 18 INSTALLING INTERNAL HARDWARE OPTIONS 20 DRAM and Additional DRAM Dual Inline Memory Modules 5 20 and PC Boards 4 225 2005 20 HAZARDOUS LOCATIONS INSTALLATION v cia vx car eek ane ae ien ve a ee ved Yea Eo oe PY ee rae ge ER D a ca 21
42. of the MAIN tab screen Use the UP and DOWN arrow keys on the keyboard to move from field to field Use the TAB key to move between HH MM SS and MM DDJ Y Y Y Y sub fields to enter the present time and date 5 Press the QWERTY keyboard F10 function key to SAVE AND EXIT 6 Lithium battery replacement is now complete The computer should boot with no error or warning messages 32 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance Product 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 below to prepare the unit for shipment 1 pure nime OUS Obtain an Return Merchandise Authorization RMA number for your unit by visiting the Pro face RMA Request web page and fill out the online request form http www profaceamerica com rma If you cannot fill out the online form there is an RMA Request Form Document that can be downloaded and either E mailed support profaceamerica com or Faxed 734 429 1010 to the Pro face Customer Support Team If you have difficulty then please call the Pro face Customer Support Team at 734 944 0482 Please have the following information e Company name shipping and billing addres
43. oller for up to 2 drives Removable 40 or 80 GB SATA hard drive s rear access AGP Video Controller 4M of system DRAM up to 32M PCI local bus IDE controller for CD DVD and CF options Two 240 pin DDR2 DIMM sockets that support 256MB 512MB 1GB and 2GB options Intel Socket 478 Celeron M or Pentium M options up to 2 0GHz 400MHz or 533MHz front side bus depending on the processor type 1546 Four AT bus expansion slots One PCI 8 0 max One PCI 9 0 max One ISA 9 0 max One PCI or ISA slot 9 0 max 1547 Four AT bus expansion slots One 1 2 length PCI One full length PCI One full length ISA One full length PCI or ISA slot IBM PS 2 keyboard port and mouse port 1 144771 A 1546 1547 Industrial PC AT Computer Systems Chapter 1 Introduction Four serial COM ports with three external ports configured as RS 232 and one configurable as either RS 232 or RS 422 or RS 485 The fourth port is an internal header only and defaulted as disabled Parallel port VGA port Four USB 2 0 ports Legacy USB keyboard and mouse support Legacy USB floppy USB CDROM and USB mass storage support Two onboard Ethernet ports one is a 10 100 BASE T and the other is 10 100 1000 BASE T Microsoft Windows XP operating system Internal rear access Compact Flash CF interface 120 240 V AC 50 60Hz Auto switching power supply UL Listed for use in Class I and Class II Division 2 hazardous locations Groups A B C D F a
44. ows 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 37 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Warning This procedure will destroy data that may exist on the hard disk drive If you want to install a new operating system or reinstall 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 AIM4 system choose the video driver for your operating system from following directory on the Documentation and Support Library CD DRIVERS AIM4 Note the video driver is part of the Intel chipset Video Expansion This section deals with the hardware expansion capability of the video controller chip in DOS applications Note It is not nec
45. posal Please note the disposal instructions as described in this section Please refer to Figure B 1 in Appendix B AIM4 CPU Board Layout The lithium battery is identified by the BT1 designation TOOLS REQUIRED 1 Long Philips Screwdriver for 6 philips screws and captive screw 2 Electrical tape to tape the old battery after removal 3 QWERTY keyboard to restore CMOS memory settings after replacing the lithium battery ESD WARNING Protective measures against electrostatic discharge ESD must be taken when working inside of any computer Failure to do so may result in permanent damage to electrical components within This damage may be immediate or latent final computer failure may occur at a later date Be sure to make consistent skin to metal contact with the computer chassis when making contact with any electrical assemblies or components TO GAIN ACCESS TO THE BATTERY AND REPLACE 1 Remove power from the 1546 1547 computer If installed in a panel the computer must be removed and placed screen down on a bench To work on the computer on the bench you must first place a soft clean cloth on the clean surface of the bench in order to prevent scratches to the display overlay or touch screen If the computer includes a front panel mouse then be sure to prop up the bottom edge of the front panel with a soft object in order to prevent damage to the panel mouse controller Do not rest the face of the computer on the
46. put power is applied to the AIM4 CPU board However electrolyte loss through the crimp seal will typically occur at the rate of approximately 0 596 per year at 20 degrees C 68 F This rate will increase with higher temperatures The 4 CPU board will consume approximately 6 uA of battery current when power is removed from the motherboard At this rate the battery will last approximately 4 2 years in storage at 21 degrees C 70 F This represents 10096 duty cycle or input power off time Example Battery Capacity 220 mAh IC Current Drain 6 uA Battery lifetime 0 22 aH 6 X 10 36 666 hours 4 2 years When input power is off at the rate of 12 hours per day continuously the battery life should be approximately double the 10046 duty cycle time or 8 4 years at 21 degrees C 5096 duty cycle When input power is off at the rate of 16 hours per day the lifetime should be approximately 12 6 years 3396 duty cycle However the electrolyte loss through the crimp seal may reduce the 3396 duty cycle lifetime somewhat Battery lifetime is inversely proportional to the temperature of the battery At elevated temperatures the battery life will be decreased BATTERY REMOVAL 29 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance Caution There is danger of the new battery exploding if it is incorrectly installed Only technically qualified personnel should perform battery replacement and dis
47. rovides 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 1546 and 1547 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 Cable A power cable must be created to supply power to the unit The following materials are needed three position power connector supplied 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 1546 1547 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 3 Tinthe wire ends with solder if using strand
48. s Type of service desired product repair or product exchange e Product model number part number quantity serial number s and warranty status e Failure mode and failure systems e Purchase order number or repair order number Make sure the front panel assembly is properly attached to the unit 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 33 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 4 Troubleshooting Chapter 4 Troubleshooting Diagnostic Testing If you suspect that you are having hardware problems with your 1546 or 1547 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 Create a DOS bootable diskette 2 Create a temporary folder on the computer hard drive 3 There is a self extracting zip file on the Documentation and Support Library CD located in DRIVERS WXComputer Diagnostics 99290 001 DOS xydiag Run that program and extract the fil
49. se 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 Location is adjacent to a Division 1 location 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 electrical equipment that is approved 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 locations may also be used in Groups B C or D Note Approved Class equipment may not b
50. se values are with solid state hard drives and not rotating media drives 41 144771 B 1546 1547 Industrial PC AT Computer Systems Appendix B AIM4 Layout Appendix B AC Model Block Diagram q 0065243 00 110 5 a 0 7 1C06720938 Figure B 1 1546 1547 System Block Diagram 42 144771 A 1546 1547 Industrial PC AT Computer Systems Appendix C Pinouts Appendix C Pinouts This appendix provides the pinouts for the keyboard mouse LPT1 COMI 2 USB and VGA connectors NC indicates No Connection Keyboard Port Connector The following table lists the signal definitions for the keyboard connector It 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 The following table lists the signal definitions for the PS 2 mini DIN mouse port connector Table C 2 Mouse Connector Pinout Pin Signal 1B MOUSE DATA NC GND 4B 5VFUSE 5B MOUSE_CLK NC 43 144771 B 1546 1547 Industrial PC AT Computer Systems Four USB Connector USB1 Appendix C Pinouts The following table lists the signal definitions for each of the four USB connectors Parallel Port Connector LPT1 Pin Table C 3 Four USB Pinout Description USBPO USBPO 5VFUSE GND The following tab
51. stallation 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 1546 1547 system CPU factory configured for many configurations of DRAM The system has two 240 pin DDR2 DIMMs that support 512 and 2GB options The maximum amount supported is 2GB You can reconfigure DDR2 capacity by changing the DDR2 DIMMs on your board 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 4 documentation Remove the lid Remove the ORB screw from the desired slot Slide the PC AT expansion board into the corresponding rail dE NN 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 1546 and or 1547 Refer to tables 2 1 and 2 2 6 Secure the board by installing the screw through the hole in the board s metal ORB and into the top of the track 7 Replace the lid 20 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation Hazardous Locations Installation Pro face designed the 1546
52. t 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 help minimize noise Potential noise generators include switching components relays solenoids motors and motor starters 17 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation 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 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 an input voltage range of 100 240V AC while still allowing the system to function within its operating margin As long as the incoming voltage is adequate the power supply p
53. tion 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 1 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 l emplacement est designe non dangereux Warning Explosion Hazard When in hazardous locations turn off power before replacing or wiring modules Avertissement Risque d Explosion Dans les situations hasardees couper la courant avant de remplacer ou de cabler les modules 22 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation 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 I Locations Class I locations are those
54. und 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 1546 Power Supply The 1546 node box has a 250 watt AC power supply with available expansion power The expansion power is limited as shown in Table 2 1 16 144771 B Table 2 1 1546 Available Expansion Current 1547 Power Supply 1546 1547 Industrial PC AT Computer Systems Voltage Available Current 3 3 VDC 4 0A 5 0 VDC 4 0A 5 0 VDC 160mA 12 0 VDC 12 0 VDC 240mA Chapter 2 Installation The 1547 node box has a 250 watt AC power supply with available expansion power The expansion power is limited as shown in Error Reference source not found Table 2 2 1547 Available Expansion Current Voltage Available Current 3 3 VDC 4 0A 5 0 VDC 4 0A 5 0 VDC 160mA 12 0 VDC 12 0 VDC 240mA 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 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 resul
55. ure and place the unit to allow easy access to the system ports see other sections in this chapter and Appendix A assure a NEMA 4 seal choose an approved enclosure that has a 14 gauge 0 075 1n 1 9 mm thick steel or 0 125 in 3 2 mm thick aluminum front face sure to account for unit s depth when choosing the depth of the enclosure 2 Create a mounting location in the enclosure see System Mounting Dimensions Be sure to place the unit at a comfortable working level Make sure the area around the mounting location is clean and free from metal burrs 3 Mount the unit position and properly secure the unit into the panel e Tighten the fourteen 10 screws to 20 inch pounds 2 597 Newton meters 23Kgf cm 4 Construct a power cable following the instructions in AC Power Cable in this chapter 10 144771 A 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation Attach one end of the power cord to the power receptacle on the unit and the other end to a properly grounded 115 230 V AC 50 60 Hz outlet e ground path from the unit chassis to the enclosure chassis can be established using the 6 32 threaded ground point hole provided on the bottom panel of the unit Turn on power to the system The system will boot up the installed operating system Install the application software via a floppy drive CD ROM or the network Additional aspects to take into account when mounting
56. use 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 1546 or 1547 unit Fuse Replacement The 1546 and 1547 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 144771 A 1546 1547 Industrial PC AT Computer Systems Chapter 3 Maintenance Figure 3 1 Fan Assembly Caution Do not operate the 1546 or 1547 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
57. ve as a default at boot time if video display devices are connected to them The Universal Serial Bus USB port is a four high USB connector that is USB 2 0 compliant One On board 10 100 Base T RJ 45 Ethernet connector with LED s and one on board 10 100 1000 Base T RJ 45 Ethernet connector with LED s 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 1546 or 1547 unit Documentation kit which includes Power connector Cable clamp and screw for strain relief of power cord Documentation and Support Library CD ROM Operating System Recovery Media or retail operating system CD ROM Mounting hardware 8 144771 B 1546 1547 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 Warning For Hazardous Locations installation review Hazardous Locations Installation in Chapter 2 before startup To prepare the system for use perform the following steps l 2 3 Attach optional keyboard to the keyboard port Attach other optional equipment following the instructions in Chapter 2 Attach th
58. vice in the fixed wiring on permanently connected equipment Avoid circuit overloading of the supply circuit 11 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation System Mounting Dimensions This section contains the mounting dimensions for the 1546 and 1547 Node Boxes 1546 Mounting Dimensions Figure 2 1 shows the vertical mounting dimensions for the 1546 Node Box Figure 2 2 shows the horizontal mounting dimensions for the 1546 Node Box ex 7 000 177 8 2 2 473 62 8 ex 7 000 177 81 7 000 177 81 e m 4xX 500 12 7 400 10 2 TYP r 4x 0 20 9511 4 200 9541 2 400 2010 2 1 400 10 2 i 9 Ca 3 1 ae pu il 4 09 103 9 6 11 155 1 6 91 175 51 5 48 139 1 ex 9 60 243 8 11 47 1291 51 1 18 79 324 8 All dimensions in inches mm Figure 2 1 1546 Vertical Mounting Dimensions with mounting rails attached 12 144771 B 1546 1547 Industrial PC AT Computer Systems Chapter 2 Installation
59. your 1546 and 1547 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 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 de

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