3 - Pro-face America
Contents
1. Chapter 3 Installation 3 5 INSTALLING INTERNAL HARDWARE OPTIONS To install any of the internal hardware options you need to first remove the universal mounting bracket refer to Figure 3 6 3 5 1 Solid State Disk Emulator Card Before installing the 4100 SSD Solid State Disk board into the 8430 jumpers and switches must be set appropriately for your particular configuration See your 4 100 SSD manual for more information After the 4100 SSD is properly configured it can be installed into the 8430 cardcage as follows 1 Turn off the power and unplug the unit from the AC wall outlet 2 Remove the 8430 equipment computer module Setthe screws aside for later use 3 Verify jumper and switch settings Refer to the 4100 SSD manual for the correct settings 4 If present remove the blank ORB from the slot that the 4100 SSD card will occupy Save the screw 5 Place the SSD card into the slots in the backplane Push down on the card evenly until it firmly seats into the card edge connectors 6 Secure the SSD ORB to the host system by replacing and tightening the screw that was removed in Step 4 7 Replace the equipment module into the 8430 and tighten the screws that were removed in Step 2 8 Plug the unit into an AC wall outlet and turn the power on 3 5 2 PC AT Boards Check that the memory and I O configuration of the board you want to install does not conflict with the CPU and I O memory maps in your CPU board manual2. Business reply card Universal mounting bracket kit Universal mounting bracket Three spacer plates Six mounting screws Four rubber feet ON OFF Switch Power Receptacle Fuse Receptacle 8430 Manual October 1994 This switch should be positioned to OFF O until the system is properly configured and connected to a 115 VAC or 230 VAC power source The power receptacle is located to the right of the ON OFF switch The plug and cord must be securely positioned before turning power ON The 2 Amp slo blo fuse is located below the power receptacle NOTE The pinouts for connectors and ports are shown in Appendix B Keyboard Connector Video Connector COMI Port COM2 Port Printer Port Fan and Filter External Battery Holder The optional keyboard 8000 KB5 8000 KB6 8000 KB7 or 8000 KB8 interfaces with the system via the five pin connector which is located at the bottom left of the input output panel The 15 pin video connector is located on the CPU board This serial port is a DB 9 connector located above the power switch The serial port is a DB 9 connector located below the fuse holder The printer port LPT1 connector is a DB 25 female located at the top of the CPU board The fan is located on the opposite panel from the input output panel at the bottom rear corner of the back panel when fully assembled The external battery holder is located below the power switch I 5 Chapter I
3. 4 000 6 968 101 60 176 99 1 484 37 69 Note All dimensions shown are in inches mm Figure 3 6 8430 Wall mounting Dimensions Position the 8430 so the disk drive is facing down onto the table then place the three spacer plates as depicted on the following page 1 Carefully place the universal mounting bracket on top of the spacers 2 Install the six screws as shown on the following page tighten screws to 21 in Ibs 3 Install the unit in the rack using standard rack mounting hardware so the drive access faces outward 4 For removal reverse the process NOTE Make sure the 8430 enclosure is grounded to the enclosure 3 9 Chapter 3 Installation Figure 3 7 Installing the Wall mounted 8430 Side 8430 Manual October 1994 3 4 8 Wall mounting and Installing the 8430 Top Position the 8430 on the table so the disk drive is facing outward then place the three spacer plates as depicted on the following page See Figure 3 6 for wall mounting dimensions 1 Carefully place the universal mounting bracket on top of the spacers 2 Install the six screws as shown on the following page tighten the screws to 21 in Ibs 3 Install the unit in the rack using standard rack mounting hardware so the drive access faces outward 4 For removal reverse the process NOTE Make sure the 8430 enclosure is grounded to the enclosure Figure 3 8 Installing the Wall mounted 8430 Top 3 1
4. Altitude Operating Sea level to 10 000ft 3048 m Non operating Sea level to 50 000 ft 15240 m HARDWARE SPECIFICATIONS T ble A 2 Hardware Specifications Mechanical Height 6 9 175 26 mm Width 15 5 393 70 mm Depth 9 5 241 30 mm Weight 25 lbs 11 34 kg Panel 19 x 7 OU Electrical 115 230 VAC 14 21 50 60 Hz 130 watts Passive Backplane 6 PC AT ISA 130 watts availableto backplane and drives 5 V 20A 4 12 V 5A 5 V and 12 V 1 5A total EIA standard 19 rack or wall A 1 Appendix B PINOUTS B 1 CONNECTING TO PLCS The 8430 can connect to a number of popular PLCs via RS 232C The pin connections for some of the supported PLCs are shown on the following pages The PLCs are listed in alphabetical order under manufacturer s name Connect shield to chassis of Xycom unit TERMINAL Figure B 1 Allen Bradley KF2 Module B I Appendix B Pinouts Connect shield to chassis of Xycom unit 3 _ eee ee 1 2 2 PL Pa 4 3 5 5 3 8430 TERMINAL 1771 KG or 1785 KE MODULE Figure B 2 Allen Bradley 1771 KG Module B 2 8430 Manual October 994 Connect shield to chassis of Xycom unit MODBUS TERMINAL 984 Figure B 3 9 pin Connection to Modbus 984 PLC B 3 Appendix B Pinouts Connect shield to chassis Xycom unit TERMINAL MODBUS 984 Figure B 4 25 pin Connection to Modbus 984 PLC B 4 Connect shield to chass
5. Introduction Diagnostic LEDs From left to right Fault Indicates the system has failed the diagnostic test Maint Indicates that there is maintenance to be done such as replacing the battery or cleaning the fan filter Power Indicates that 5VDC is present Disk Indicates hard disk activity when on or flashing COM Indicates COMI or COM2 port activity when on or flashing RADAR Indicates Run Time Diagnostics has detected an error 1 5 QUICK START UP NOTE At minimum you should read this section and the appendices This section gets your system running without explaining options or capabilities of the system The appendices provide pinouts error messages setup information specifications etc To prepare the system for use perform the steps listed below WARNING Turn the power to the unit off and unplug the power cord while making any adjustments to the inside or outside of the terminal WARNING If the battery is disabled in your system upon enabling you must power up your system for a minimum of 30 seconds Failure to follow this procedure may result in premature battery failure Connect the video cable from the VGA video monitor to the CRT video connector on the 8430 Attach optional keyboards mouse e Connect an external full stroke keyboard to the keyboard connector e A serial mouse can be connected to the serial port on the unit Attach other optional equipment 8430 Manual October 1994 4 Attach
6. 1 Turn off the power and unplug the 8430 from the AC wall outlet 2 Remove the 8430 equipment computer moduel Set the screws aside for later use 3 Remove the ORB screw in the desired track 4 Slide the PC AT board into a corresponding rail 3 12 8430 Manual October 1994 S Push the board into the backplane connectors NOTE DO NOT force the boards or apply uneven pressure 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 equipment module into the 8430 and tighten the screws that were removed in Step 2 8 Plug the unit into an AC wall outlet and turn the power on 3 6 INSTALLING EXTERNAL HARDWARE OPTIONS This section explains how to install the external hardware options available with the 8430 3 6 1 Keyboards Four keyboards are available for the 9475 9485 9486 the 8000 KB5 8000 KB6 8000 KB7 and 8000 KB8 Listed below are the features of each keyboard 8000 KB5 A rack or panel mounted NEMA 4 104 key QWERTY keyboard with PC AT interface 8000 KB6 A rack or panel mounted NEMA 4 numeric keyboard with 52 function keys 8000 KB7 A stand alone 104 key QWERTY NEMA 4 keyboard 8000 KB8 A stand alone numeric NEMA 4 keyboard with 42 function keys 3 13 Chapter 3 Installation The keyboards are installed in the same manner Mount them according to the cutout in Appendix B Once the keyboard is mounted connect the keyboard c
7. 5 Installing the Rack mounted 8430 3 8 3 6 8430 Wall mounting Dimensions 3 9 3 7 Installing the Wall mounted 8430 side 3 8 Installing the Wall mounted 8430 top 3 11 3 9 8000 KB5 and 8000 KB6 Cutouts 3 14 4 Fuse Holder Access Door 4 4 2 Changing the Fan Filter 4 4 4 3 Changing the Battery 4 5 B 1 Allen Bradley KF2 Module B 1 B 2 Allen Bradley 1771 KG Module B 2 B 3 9 pin Connection to Modbus 984 PLC B 3 B 4 25 pin Connection to Modbus 984 PLC B 4 B 5 Omron PLC B 5 B 6 Texas Instruments Series 500 PLC B 6 B 7 Texas Instruments 545 PLC B 7 B 8 Westinghouse PLC B 8 iii Chapter 1 INTRODUCTION 1 1 PRODUCT OVERVIEW The 8430 Industrial Computer Node Box puts the power and versatility of an IBM PC AT compatible computer in a package that makes sense for the factory floor and other harsh environments The Xycom 8430 Industrial PC AT Computer System features an open ended design to meet a wide variety of applications when both a powerful PC and a durable industrial enclosure are required The system integrates the computer card cage mass storage and power supply in a truly industrial form factor The 8430 system includes a six slot passive AT backplane and hard and floppy disk drive facilities The open architecture design accepts IBM PC XT or AT compatible cards The system s relocatable equipment module design allows easy access to the boards switches power supply and disk drives Many software packages are comp
8. 8430 Industrial Node PC AT Computer System PIN 99663 001A 1994 XYCOM INC XYCOM 750 North Maple Road Printed in the United States of America Saline Michigan 48176 1292 Part Number 99663 001A 313 429 4971 XYCOM REVISION RECORD Revision Description A Manual Released Trademark Information Brand or product names are registered trademarks of their respective owners CopyrightInformation This document is copyrighted by Xycom Incorporated Xycom and shall not be reproduced or copied without expressed written authorization from Xycom The information contained within this document is subject to change without notice Xycom does not guarantee the accuracy of the information and makes no commitment toward keeping it up to date Address comments concerning this manual to xycom Technical Publications Department 750 North Maple Road EAZL Saline Michigan 48176 1292 Part Number 99663 00IA CHAPTER 1 Ree eee He UR BR RwWNE Ne 2A 22 2 3 3 1 3 2 3 3 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 3 4 7 3 4 8 3 5 Sl 3 5 2 ww W W gt I DD NR TITLE INTRODUCTION Product Overview Product Features Unpacking the System System Components Front Panel Components Input Output Panel Components Quick Start up TESTING Diagnostic Tests Preparing for the Tests Running the Tests INSTALLATION Introduction Drive Access Panel Preparing the System for Use Installing
9. Main Menu 2 3 preparing for 2 1 running 2 2 Diagnostics Main Menu 2 3 Disk LED 1 6 Documentation kit 1 2 Drive access panel 3 4 Drives accessing 3 4 E Electrical specifications A 1 Electromagnetic interference 3 5 Enclosure 3 5 Environmental specifications A 1 External hardware options installation 3 13 F Failure 2 1 Fan 1 5 Fan filter cleaning 4 1 replacing 4 3 Fault LED 1 6 Filter 1 5 Front panel components 3 1 Fuse 1 2 receptacle 1 5 replacement 4 2 G Grounding 3 6 H Hardware specifications A 1 depth A 1 electrical A 1 height A 1 panel A 1 passive backplane A 1 weight A 1 width A 1 Heat excessive 3 6 I I Index H continued Height A 1 Humidity 4 1 Installation 3 1 external hardware options 3 13 internal hardware options 3 12 keyboards 3 13 MS DOS 3 15 PC AT boards 3 12 rack or panel 3 5 serial mouse 3 14 Solid State Disk Emulator Card 3 12 Interference electromagnetic 3 5 radio frequency 3 5 Internal components 3 3 Internal hardware options installation 3 12 J Jumpers setting 2 1 K Keyboard connector 1 5 Keyboards cutouts 3 13 installation 3 13 optional 1 5 L LEDs diagnostic 1 3 1 6 COM 1 6 Disk 1 6 Fault 1 6 Maint 1 6 Power 1 6 RADAR 1 6 Line voltage excessive 3 7 LPT1 1 5 M Main Menu Diagnostics 2 3 Maint LED 1 6 Maintenance connections 4 1 dusting 4 1 fan filter 4 1 Maintenance continued location of noise generating equipm
10. OWER SUPPLY 8430 Manual October 1994 BATTERY SPEAKER ON OFF HOLDER SWITCH Figure 3 3 Internal System Components 3 3 Chapter 3 Installation 32 DRIVE ACCESS PANEL Remove the four screws located on the lip of the drive access panel Pull down the panel to access the drives THIRD DRIVE COVER FLOPPY DRIVE REMOVABLE ri HINGE PIN TE HINGE BOTTOM PLATE HARD DRIVE SHOCK MOUNTS 4 SECOND if Ly Mardorve I MUNIE OPTIONAL CONNECTOR ANY E THIRO DRIVE LOCATION P10 SE j FLOPRY DRNE Figure 3 4 Drive Access Panel 3 3 PREPARING THE SYSTEM FOR USE To prepare the system for use perform the steps listed below If you have purchased any options install them according to the instructions in the next sections 1 Attach the power cord by attaching one end to the power receptacle and the other to a properly grounded 1150r 230 VAC outlet 2 Connect the video cable from the 8430 to the video connector on the external monitor 3 4 3 4 8430 Manual October 1994 INSTALLING THE SYSTEM INTO A RACK OR PANEL The 8430 s rugged design allows it to be installed in most industrial environments The unit is generally placed in a NEMA 4 12 enclosure to protect against contaminants such as dust moisture etc Metal enclosures also help minimize the effects of electromagnetic radiation that may be generated by nearby equipment 3 4 1 Mounting Considerations Fol
11. TIVE MAINTENANCE The 8430 was designed to withstand the harsh environment of the factory floor Routine maintenance can help keep your 8430 in good operating condition Preventive maintenance consists of several basic procedures and checks that will greatly reduce the chances of system malfunction Preventive maintenance should be scheduled along with the regular equipment maintenance to minimize 8430 down time Some preventive measures are listed below Clean or change the fan filter periodically to ensure that the air circulating in the unit is clean Filter maintenance should not be put off until the scheduled maintenance but should be performed periodically depending on the amount of dust in the area 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 shock could loosen the connections Check to see that all plugs sockets terminal strips and module connections are solid Do not move noise generating equipment too near the 8430 Stock spare parts to minimize down time resulting from part failure The spare parts stocked should be 10 percent of the number of each unit used The main CPU card should have one spare each regardless of the number of CPUs used Each power supply should have a back
12. able to the keyboard port 3 156 pla 6 00 80 16 152 40 16240 re 3 156 4 80 16 o 1 98 50 29 as se 17 100 434 34 o 7 96 202 18 N sie 7 00 177 80 1 98 50 29 o 48 12 19 25 6 35 diameter holes Se 465 12 hi Depth 0 25 6 35 All dimensions shown in inches mm 61 15 49 Figure 3 9 8000 KB5 and 8000 KB6 Cutouts 3 14 8430 Manual October 1994 3 6 2 Serial Mouse To install Xycom s 4100 MS1 three button serial mouse attach the connector on the mouse cable to one of the serial port connectors COM1 or COM2 on the input output panel of the 8430 3 7 INSTALLING MS DOS The unit ships with MS DOS installed If you need to reinstall MS DOS follow the instructions below 1 Turn off power to the system 2 Insert the MS DOS Install disk into drive A 3 Turn on the power 4 Wait for the DOS prompt to appear on the screen 5 Type A install or B install and follow any instructions on the screen For more information see your MS DOS manuals 3 8 DERATING THE POWER SUPPLY On the average the temperature within the 8430 is 7 10 higher than that outside the enclosure When the ambient exterior temperature reaches 42 C the system s power supply will begin to derate at a rate of 3 25 watts per increase of 1 C The 8430 is rated to work at temperatures up to 50 C At 50 C the power supply should be derated to 104 W of total available power with
13. at certain times may appear at widely spread intervals or in some cases may exist continuously Noise usually enters through input output and power supply lines and may be coupled into lines electrostatically through the capacitance between these lines and the noise signal carrier lines This usually results from the presence of high voltage or long closely spaced conductors When communication lines are closely spaced with lines carrying large currents the coupling of magnetic fields can also occur Use shielded cables to help minimize noise Shielded communication cables should be grounded at the unit end only Potential noise generators include relays solenoids motors and motor starters especially when operated by hand contacts like push buttons or selector switches In accordance with National Electrical Code specifications 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 the PLC communication cables 3 4 5 Excessive Line Voltage The power supply section of the 8430 is built to sustain line fluctuations of 90 226 VAC and still allow 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 J O In cases in which the installation is subject to unusual AC line variations a c
14. atible with the 8430 including the following e AIMAX PLUS e MICRO VIEW e Cellworks e MULTI VIEW DMACS e 01 2000 e Development Series e ONSPEC e Factory Link e Paragon 500 e The FIX e PCIM e FloPro e PLANT VIEW e GENESIS e ScreenWare2 e InTouch e Softscreen PC AT e Ladder Logic e Viewpoint e Microtie This software list is continually expanding Consult Xycom for additional listings Chapter I Introduction 1 2 PRODUCT FEATURES Features of the 8430 include the following Six slot AT passive backplane with power status LEDs IDE hard disk drive 3 5 inch 1 44 Mbyte floppy drive MS DOS installed on the hard disk 130 watt power supply IBM PC AT XT compatibility External printer port External COMI and COM ports Super VGA support Optional items available with the 8430 include the following 1 3 4100 SSD Solid State Drive emulator 8000 KB5 rack or panel mounted QWERTY membrane keyboard 8000 KB6 rack or panel mounted NUMERIC membrane keyboard 8000 KB7 desktop or panel mounted QWERTY membrane keyboard 8000 KB8 desktop or panel mounted NUMERIC membrane keyboard 4100 MS1 three button serial mouse UNPACKING THE SYSTEM After removing the 8430 from its box verify that you have the parts listed below Save the box and inner wrapping in case you need to reship the unit I 2 8430 unit Documentation kit which includes Power cable Test software diskette Two spare fuses 8430 user manual
15. ent 4 1 preventive 4 1 routine 4 2 Memory resident programs 2 1 Modbus 984 Electrical Interface B 4 Modbus 984 PLC B 3 Module replacing 4 1 Mounting 3 5 rack 3 7 4 1 specifications 4 1 wall 3 9 3 11 4 1 MS DOS installation 3 15 N National Electric Code 3 6 Noise excessive 3 7 4 1 O Omron PLC B 5 Optional equipment attaching 1 6 P Panel A 1 Passive backplane A 1 PC components cleaning 4 1 PC AT boards installation 3 12 Pinouts B 1 Allen Bradley 1771 KG Module B 2 Allen Bradley KF2 Module B 1 Modbus 984 PLC B 3 Modbus 984 Electrical Interface B 4 Omron PLC B 5 Texas Instruments 545 PLC B 7 Texas Instruments Series 500 PLC B 6 Westinghouse PLC B 8 PLCs connecting to B 1 Allen Bradley 1771 KG Module B 2 Modbus 984 Electrical Interface B 4 Modbus 984 B 3 Omron B 5 Texas Instruments 545 B 7 Texas Instruments Series 500 B 6 Westinghouse B 8 Ports COMI 1 5 COM 1 5 printer 1 5 Power LED 1 6 P continued Power lines placement 3 5 Power receptacle 1 5 Power supply derating 3 15 requirements 3 15 Power system 3 6 PR amp C see Product Repair amp Customization Department 4 6 Printer port 1 5 Product Repair amp Customization Department 2 1 4 6 Q Quick start up 1 6 R Rack mounting 3 7 RADAR LED 1 6 Radio frequency interference 3 5 Repairing a unit 4 5 Returning a unit 4 5 RMA number 4 6 RS 232C 4 1 S Serial loopback connector 2 2 Serial mouse installation 3 15 S
16. etup accessing 2 1 exiting 2 1 saving 2 1 Setup Menu 2 1 Slo blo fuse 4 2 Software compatibility 1 1 Solid state disk emulator card see 4100 SSD Spare parts 4 1 4 3 Specifications environmental A 1 hardware A 1 Switch ON OFF 1 5 Switches setting 2 1 System grounding 3 4 preparing for use 3 4 System components 1 3 back panel 3 2 front panel 1 3 3 1 8430 Manual October 1994 System components continued input output panel 1 4 internal 3 3 System power 3 6 System unpacking 1 2 T Temperature 3 6 3 15 4 1 Tests diagnostic 2 1 Texas Instruments 545 PLC B 7 Texas Instruments Series 500 PLC B 6 U Universal mounting bracket kit 1 2 Unpacking the system 1 2 V Video connector 1 5 Voltage 3 7 W Wall mounting 3 9 3 11 Weight A 1 Westinghouse PLC B 8 Width A 1 I 3
17. exceed the unit s shock vibration and temperature specifications 3 5 Chapter 3 Installation 3 4 2 System Power It is always a good practice is to use isolation transformers on the incoming AC power line to the unit 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 National Electric Code NEC article 250 which provides 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 The following practices should be observed e Separate ground wires 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 All electrical racks or chassis and machine elements should be grounded to a central ground bus normally located near the point of entry for the plant power su
18. is of Xycom unit TERMINAL OMRON PLC Figure B 5 Omron PLC 8430 Manual October 1994 Appendix B Pinouts Connect shield to chassis of Xycorn unit as 1 els 8430 TERMINAL Figure B 6 Texas Instruments Series 500 PLC B 6 8430 Manual October 1994 Connect shield to chassis of Xycorn unit RXD 1o O RXD e Do x xp Su es eo 4o i i e 5 T 545 PLC TERMINAL Figure B 7 Texas Instruments 545 PLC B 7 Appendix B Pinouts Connect shield to chassis of Xycom unit 14 mee 2 RxD els TERMINAL WESTINGHOUSE PLC Figure B 8 Westinghouse PLC Numerical 4100 SSD card 3 12 8000 KB5 3 13 8000 KB6 3 13 8000 KB7 3 13 8000 KB8 3 13 8430 features 1 2 optional items 1 2 overview 1 1 A AC power cable 2 1 Allen Bradley 1771 KG Module B 2 Altitude A 1 B Back panel components 3 2 Backplane passive A 1 Battery replacement 4 4 Battery external 1 5 BIOS setup information 2 3 C Cables AC power 2 1 printer 2 2 CMOS TXT 2 3 COM LED 1 6 COMI port 1 5 COM2 port 1 5 Compatibility software 1 1 Condensation 3 5 Connecting to PLCs B 1 Connections checking B 1 Connectors keyboard 1 5 2 2 serial loopback 2 2 video 1 5 Current available 3 15 D Default settings 2 1 Depth A 1 Derating power supply 3 15 Device drivers 2 1 DIAG TXT 2 3 INDEX Diagnostic disks CMOS TXT 2 3 DIAG TXT 2 3 Diagnostic tests 2 1 disk 2 2 equipment 2 1
19. low these guidelines for installing your 8430 Select an enclosure and place the unit to allow easy access to the ports Account for the unit s depth as well as cabling when choosing the depth of the enclosure Mount the unit in an upright position Place the unit at a comfortable working level Consider locations of accessories such as AC power outlets and lighting interior lighting and windows for installation and maintenance convenience If condensation is expected install a thermostat controlled heater or air conditioner To allow for maximum cooling avoid obstructing the air flow Place fans or blowers close to the heat generating devices If using a fan make sure that outside air is not brought inside the enclosure unless a fabric or other reliable filter is used This filtration prevents conductive particles or other harmful contaminants from entering the enclosure Do not select a location near equipment that generates excessive electromagnetic interference EMI or radio frequency interference RFI equipment such as 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 suppressors away from the unit 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
20. onstant voltage transformer can be used 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 a constant voltage transformer must be used The constant voltage transformer stabilizes the input voltage to the unit 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 3 4 6 Rack mounting and Installing the 8430 Position the 8430 on the table so the disk drive is facing up then place the three spacer plates as depicted on the following page 1 Carefully place the universal mounting bracket on top of the spacers 2 Install the six screws as shown on the following page tighten the screws to 21 in lbs 3 Install the unit in the rack using standard rack mounting hardware so the drive access faces outward 3 7 Chapter 3 Installation 4 For removal reverse the process NOTE Make sure the 8430 enclosure is grounded to the enclosure Figure 3 5 Installing the Rack mounted 8430 3 8 8430 Manual October 1994 3 4 7 Wall mounting and Installing the 8430 Side The 8430 wall mounting dimensions are illustrated below 19 000 482 60 18 312 465 12 344 8 74 1 484 37 69
21. plements engineering changes that enhance operating specifications Products returned to Xycom will be tested with standard Xycom test diagnostics Contact the PR amp C Department for information on turnaround times Follow the steps below to prepare the unit for shipment 1 Obtain an RMA number for your unit by calling your local Product Repair Department or Xycom Repair Center Have the following information available e Company name and 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 e Purchase order number or repair order number You will then receive your RMA number This number must appear on the outside of the shipping container and on the purchase order 2 Maxke sure the unit is properly assembled and all components are secured 3 Attach failure information to the unit to speed processing Chapter 4 Maintenance 4 Place the unit securely in a heavy duty box 5 Mark the RMA number on your purchase order and on the outside of the box 6 Send the unit to your local Xycom repair center 4 6 A 1 A 2 Appendix A SPECIFICATIONS ENVIRONMENTAL SPECIFICATIONS Table A 1 Environmental Specifications Temperature Operating 0 to 50 C 32 to 122 F Non operating 40 to 60 C 40 to 140 F Humidity Operating 10 to 80 RH non condensing
22. pply of the enclosure Paint and other nonconductive material should be scraped away from the area where a chassis makes contact with the enclosure In addition to the ground connection made through the mounting bolt or stud a one inch metal braid or size 8 AWG wire can be used to connect between each chassis and the enclosure at the mounting bolt or stud e The enclosure should be properly grounded to the ground bus Make sure a good electrical connection is made at the point of contact with the enclosure e The machine ground should be connected to the enclosure and to earth ground 3 4 3 Excessive Heat The 8430 is designed to withstand temperatures from 0 to 50 C The systems are cooled by convection in which a vertical column of air is drawn in an upward direction over the surface of its components To keep the temperature in range the cooling air at the base of the system must not exceed 50 C Proper spacing must also be allocated between internal components installed in the enclosure When the air temperature is higher than 50 C in the enclosure use a fan or air conditioner 3 6 8430 Manual October 1994 3 4 4 Excessive 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 due to operating errors which can result in hazardous machine operation in certain applications Noise may be present only
23. r Centronics style interface e Two serial loopback test connectors refer to Figure 2 1 for pinouts e Scratch disk formatted 3 5 inch DS HD 1 44 Mbyte 2 2 PREPARING FOR THE TESTS Perform the steps below before starting the system tests 1 Place the CPU boardjumpers and switches to the factory set positions Refer to your CPU manual for these settings 2 Plug the female end of the AC power cable into the rear of the unit and the male end into a properly grounded outlet Copyright 1990 1994 Xycom Inc All 8430 Manual October 1994 rights reserved Diagnostic Tests Sequence Selection Menu Rel xx WILL pause on an error SINGLE PASS test mode Save setup to file Extract setup froma file RAM Test Video RAM Test Extended RAM Test Time Clock Test Serial Port Test Serial Port Test Serial Port Test COM4 Serial Port Test Math Coprocessor Test Video Adjustments Test Real COM COM2 COM3 Auto sel 5 Return ect Deselect all Quit and exit to DOS to Previous screen tests tests Video Interface Test Speaker Port LPT1L Printer LPT2 Printer C Hard Driv Test Port Test Test fac D Hard Driv B F Keyboard A Floppy Drive In oppy Drive Interf 4 rfac terf Keypad Tests Tes
24. t Selected ENTER Use the letters to move the arrow keys to move then us EST START T th select deselect a test or function NG the cursor and select deselect SPACE key to or use Figure 2 2 Diagnostics Main Menu Pleas NOTE You can select tests individually However we recommend you use Auto select 4 which selects all tests appropriate to your configuration R etabe read the DIAG TXT and CMOS TXT files on the diagnostics disk for itefarled information Refer to the CMOS TXT file for BIOS setup information 2 3 Chapter 3 INSTALLATION 3 1 INTRODUCTION This chapter discusses how to install options into the 8430 The figures on the next three pages show components on the front panel back panel and inside the unit to help locate features relevant to installation Diagnostic LEDs are only on the 8430 525X and 6254 configurations M MOUNTING HOLES POWER DISK MAINT com N THIRD DISK DRIVE FLOPPY DISK DRIVE COVER PLATE Figure 3 1 8430 Front Panel Chapter 3 Installation M MOUNTING HOLES A AC POWER SUPPLY SCREWS I Y O o O o FAN M M M M n o o ONOFF S IS SWITCH A A l o O He oo B A A C gt o o o SPEAKER tj I o o O o BOTTOM M M PLATE HINGE d Figure 3 2 8430 Back Panel 3 2 DIAGNOSTIC LED s BOARD GUIDES BACKPLANE FLOPPY Pe 34 J3 U2 31 FAN P
25. t operate the 8430 without a fan filter Dust build up could cause the unit to malfunction Chapter 4 Maintenance Figure 4 2 Changing the Fan Filter 4 2 4 Replacing the Battery The 8430 has a backup battery for the system RAM mounted on the back panel above the secondary serial port Tum the slotted batter holder cap see Figure 4 3 and remove the battery Replace with an AA 3 6 V lithium battery CAUTION DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED Replace only with the same or equivalent type recommended by the manufacturer Dispose of used batteries according to the manufacturer s instructions Bei falschem Umgang mit oder falschem Einbau einer Lithium Batterie kann eine Explosion entstehen bel der in der Nahe befindliche Personen schwere Verietzungen erieiden konnen Versuchen Sie nicht Lithium Batterien wieder aufzuiaden kurzzuschliessen oder zu ottnen und werfen Sie sie nicht in den Mull oder in ein Feuer Wechsein Sie sie nur gegen gensu den gleichen Typ aus Zur Entsorgung mussan Sie Lithium Batterien an ihren Handler zuruckgeben Reverse the procedure to install the new battery Ensure that the pole of the battery is oriented toward the cap 4 4 8430 Manual October 1994 Figure 4 3 Changing the Battery 4 3 PRODUCT REPAIR PROGRAM RETURNING A UNIT TO XYCOM Xycom s Product Repair amp Customization Department PR amp C restores equipment to normal operating condition and im
26. the AT4SLC board installed or 80 W with the AT4 board installed Refer to Table 3 1 on the following page for more information 3 15 Chapter 3 Installation Table 3 1 Derating Example 5 VDC 12 VDC 2 VDC 3 VDC Total Current Available Before De rating not to exceed 130 w 20A 5A 1A LA Total Current Available After De Rating at 50 C ambient outside not 16A 4A 0 8A 0 8A to exceed 104 W 8430 Configured Current Required AT4SLC AT4 2 60 3 75A Hard disk 32 A Floppy disk 1 0A Fan 0 Minimum Load Resistor 2 0 A Total maximum 5 92 7 07 A OS A 8430 Expansion Current Available 10 08 8 93 A 3 19 A 75A 08A NOTE The 130 watt power supply requires a 3 amp minimum load on 5 volts If more than 11 58 Amps is required and the minimum load requirements are meet with the expansion cards two additional amps become available by disconnecting the minimum load resistor It is acceptable to draw slightly more current than is specified for expansion current as long as the total wattage drawn does not exceed 104 watts at 50 C and you do not exceed the current available before derating 3 16 Below is a derating example of an 8430 with an AT4 board installed 5 92Ax5v 29 60 W O81Ax 12 9 72 W 0 75Ax l2v 9 00 W 0 80 A x 5v 4 00 W 52 32 W 104 W 52 32 W 51 68 W 51 68 W available for expansion cards 8430 Manual October 1994 3 I7 4 1 Chapter 4 MAINTENANCE PREVEN
27. the System into a Rack or Panel Mounting Considerations System Power Excessive Heat Excessive Noise Excessive Line Voltage Rack mounting and Installing the 8430 Wall mounting and Installing the 8430 Side Wall mounting and Installing the 8430 Top Installing Internal Hardware Options Solid State Disk Emulator Card PC AT Boards Installing External Hardware Options Keyboards Serial Mouse Installing MS DOS Derating the Power Supply TABLE OF CONTENTS PAGE 3 6 3 7 3 7 3 9 3 11 3 12 3 12 3 12 3 13 3 13 3 15 3 15 3 15 Table Contents CHAPTER 4 4 1 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 3 A B TABLE 3 1 4 1 A 1 A 2 FIGURE 1 1 1 2 2 1 2 2 3 1 3 2 3 3 3 4 ii TITLE MAINTENANCE Preventive Maintenance Maintenance Replacing the Fuse Spare Parts List Changing the Fan Filter Replacing the Battery Product Repair Program Returning a Unit to Xycom APPENDICES SPECIFICATIONS PINOUTS LIST OF TABLES TITLE Derating Example Spare Parts List Environmental Specifications Hardware Specifications LIST OF FIGURES TITLE Front Panel Components 8430 525X 6254 Input Output Panel Components Serial Loopback Connections Diagnostics Main Menu 8430 Front Panel 8430 Back Panel Internal System Components Drive Access Panel PAGE PAGE 3 16 4 3 A 1 A 1 2 2 2 3 3 1 3 2 3 4 8430 Manual October 1994 LIST OF FIGURES continued FIGURE TITLE PAGE 3
28. the power cord from the power receptacle to a properly grounded 115 or 230 VAC outlet I Turn on power to the unit The system will boot up at the C prompt 6 Install application software via the floppy disk drive I 7 Chapter 2 TESTING 251 DIAGNOSTIC TESTS Diagnostic tests are provided as a tool to verify the operation of the 8430 system hardware functions If any of these tests fail either you do not have the correct default setting or there is a failure Check the default settings and run the tests again If there is another failure contact Xycom s Product Repair amp Customization Department refer to Section 4 3 NOTE Unexpected failures may occur if Xycom diagnostics are run with device drivers or memory resident programs installed on the system Remove these before running any diagnostic tests Make sure the Setup Menu is configured properly factory set configuration To enter the Setup Menu press Ctrl A1lt S simultaneously after the post RAM test has completed Make the necessary changes by following directions on the screen Press F10 to save the Setup and Esc to exit Refer to your CPU manual for more information on the Setup Menu To test your system you need the following equipment e Xycom System Test Disk 3 5 inch DS DD disk bootable part number 99290 001 e IBM PC AT compatible keyboard Xycom part number 91971 001 or equivalent e Centronics compatible printer cable e Parallel printe
29. up In certain applications where immediate operation of a failed system is required an entire spare unit may need to be stocked See the spare parts list in Table 4 1 When replacing a module make sure it is the correct type If the new module solves the problem but the failure reoccurs after a while check for inductive loads that may be generating voltage and current spikes that may require external suppression Chapter 4 Maintenance 4 2 MAINTENANCE This section describes maintenance procedures for the 8430 4 2 1 Replacing the Fuse The 8430 uses a standard 2 Amp slo blo fuse The fuse holder access cover is located on the 1 Qanel refer to Section 1 4 2 CAUTION Tum off the power to the terminal before removing the fuse Figure 4 1 Fuse Holder Access Door 8430 Manual October 1994 4 2 2 Spare Parts List Use the part numbers specified below when you need to re order parts for your 8430 unit Table 4 1 Spare Parts Lists Part Number AT4SLC O Mbytes 99 142 025 AT4SX 0 Mbytes 99298 133 AT4DX 0 Mbytes 99298 233 AT4DX2 0 Mbytes 99298 266 4100 SSD 94669 005 Hard Drive 170 Mbytes 99344 001 270 Mbytes 9942 1 001 540 Mbytes 99423 001 2 A Slo Blo Fuse 01054 001 Power Cord 88760 001 VGA Video Cable 96246 001 4 2 3 Changing the Fan Filter To change the fan filter remove the grill and filter as illustrated in Figure 4 2 Clean the filter and snap the grill back into position CAUTION Do no
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