Octagon 5445, 5445E User Manual

NOTICE

The drivers and utilities for Octagon products, previously provided

on a CD, are now in a self-extracting zip file located at the Octagon

Systems web site on the product-specific page. Download this file to a
separate directory on your hard drive, then double click on it to extract
the files. All references in this manual to files and directories on the CD

now refer to files in the Utilities zip file.

O C T A G O N

S Y S T E M S

Embedded PCs For Extreme Environments

5445/5445E Video / Ethernet Card

User’s Manual

5782(0105)

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Copyright

Micro PC™, PC SmartLINK™, CAMBASIC, Octagon Systems

®

Corporation

, the Octagon logo and the Micro PC logo are trademarks

of Octagon Systems Corporation.

Disclaimer

Copyright 2001, 2005— Octagon Systems Corporation. All rights
reserved. However, any part of this document may be reproduced,
provided that Octagon Systems Corporation is cited as the source. The
contents of this manual and the specifications herein may change
without notice.

The information contained in this manual is believed to be correct.
However, Octagon assumes no responsibility for any of the circuits
described herein, conveys no license under any patent or other right,
and makes no representations that the circuits are free from patent
infringement. Octagon makes no representation or warranty that such
applications will be suitable for the use specified without further
testing or modification.

Octagon Systems Corporation general policy does not recommend the
use of its products in life support applications where the failure or
malfunction of a component may directly threaten life or injury. It is a
Condition of Sale that the user of Octagon products in life support
applications assumes all the risk of such use and indemnifies Octagon
against all damage.

st

6510 W. 91

Ave.

Westminster, CO 80031

Technical support: 303–426–4521
Telephone: [phone]
FAX: [phone]
Web site: www.octagonsystems.com

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IMPORTANT!

Please read the following section before installing your product:

Octagon’s products are designed to be high in performance while
consuming very little power. In order to maintain this advantage,
CMOS circuitry is used.

CMOS chips have specific needs and some special requirements that
the user must be aware of. Read the following to help avoid damage to
your card from the use of CMOS chips.

≡ Using CMOS circuitry in industrial control

Industrial computers originally used LSTTL circuits. Because many
PC components are used in laptop computers, IC manufacturers are
exclusively using CMOS technology. Both TTL and CMOS have failure
mechanisms, but they are different. Described below are some of the
failures which are common to all manufacturers of CMOS equipment.
However, much of the information has been put in the context of the
Micro PC.

Octagon has developed a reliable database of customer–induced, field
failures. The average MTBF of Micro PC cards exceeds 11 years, yet
there are failures. Most failures have been identified as customer–
induced, but there is a small percentage that cannot be identified. As
expected, virtually all the failures occur when bringing up the first
system. On subsequent systems, the failure rate drops dramatically.

 Approximately 20% of the returned cards are problem–free. These

cards, typically, have the wrong jumper settings or the customer
has problems with the software. This causes frustration for the
customer and incurs a testing charge from Octagon.

 Of the remaining 80% of the cards, 90% of these cards fail due to

customer misuse and accident. Customers often cannot pinpoint
the cause of the misuse.

 Therefore, 72% of the returned cards are damaged through some

type of misuse. Of the remaining 8%, Octagon is unable to
determine the cause of the failure and repairs these cards at no
charge if they are under warranty.

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The most common failures on CPU cards are over voltage of the power
supply, static discharge, and damage to the serial and parallel ports.
On expansion cards, the most common failures are static discharge,
over voltage of inputs, over current of outputs, and misuse of the
CMOS circuitry with regards to power supply sequencing. In the case
of the video cards, the most common failure is to miswire the card to
the flat panel display. Miswiring can damage both the card and an
expensive display.

 Multiple component failures: The chance of a random

component failure is very rare since the average MTBF of an
Octagon card is greater than 11 years. In a 7-year study, Octagon
has never
caused by misuse or accident. It is very probable that multiple
component failures indicate that they were user–induced.

found a single case where multiple IC failures were not

 Testing “dead” cards: For a card that is “completely

nonfunctional”, there is a simple test to determine accidental over
voltage, reverse voltage or other “forced” current situations.
Unplug the card from the bus and remove all cables. Using an
ordinary digital ohmmeter on the 2,000 ohm scale, measure the
resistance between power and ground. Record this number.
Reverse the ohmmeter leads and measure the resistance again. If
the ratio of the resistances is 2:1 or greater, fault conditions most
likely have occurred. A common cause is miswiring the power
supply.

 Improper power causes catastrophic failure: If a card has

had reverse polarity or high voltage applied, replacing a failed
component is not an adequate fix. Other components probably
have been partially damaged or a failure mechanism has been
induced. Therefore, a failure will probably occur in the future. For
such cards, Octagon highly recommends that these cards be
replaced.

 Other over–voltage symptoms: In over–voltage situations, the

programmable logic devices, EPROMs and CPU chips, usually fail
in this order. The failed device may be hot to the touch. It is
usually the case that only one IC will be overheated at a time.

 Power sequencing: The major failure of I/O chips is caused by

the external application of input voltage while the Micro PC power
is off. If you apply 5V to the input of a TTL chip with the power off,
nothing will happen. Applying a 5V input to a CMOS card will
cause the current to flow through the input and out the 5V-power
pin. This current attempts to power up the card. Most inputs are
rated at 25 mA maximum. When this is exceeded, the chip may be
damaged.

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 Failure on powerup: Even when there is not enough current to

destroy an input described above, the chip may be destroyed when
the power to the card is applied. This is due to the fact that the
input current biases the IC so that it acts as a forward biased
diode on powerup. This type of failure is typical on serial interface
chips but can apply any IC on the card.

 Under rated power supply: The board may fail to boot due to an

under rated power supply. It is important that a quality power
supply be used with Octagon Systems cards that has sufficient
current capacity, line and load regulation, hold up time, current
limiting, and minimum ripple. It is extremely import to select a
supply that ramps up in 10ms or less. This assures that all the
circuitry on the CPU cards sequences properly and avoids system
lockup.

 Excessive signal lead lengths: Another source of failure that

was identified years ago at Octagon was excessive lead lengths on
digital inputs. Long leads act as an antenna to pick up noise. They
can also act as unterminated transmission lines. When 5V is
switch onto a line, it creates a transient waveform. Octagon has
seen submicrosecond pulses of 8V or more. The solution is to place
a capacitor, for example 0.1 µF, across the switch contact. This will
also eliminate radio frequency and other high frequency pickup.

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Table of Contents

≡ Using CMOS circuitry in industrial control........................................................................... 3

Table of Contents ............................................................................................................................6

List of Figures .................................................................................................................................8

List of Tables ...................................................................................................................................8

Chapter 1: Overview ......................................................................................................................9

≡ Description ............................................................................................................................... 9

Video......................................................................................................................................... 9

Ethernet ................................................................................................................................... 9

Chapter 2: Installation ................................................................................................................10

≡ Hardware installation ........................................................................................................... 10

Using a Micro PC card cage .................................................................................................. 10

Component Location..............................................................................................................11

≡ Connecting the monitor/display ............................................................................................ 13

Analog Monitor ...................................................................................................................... 13

Flat Panel Display ................................................................................................................. 14

Programming the 5445 EEPROM ........................................................................................ 15

≡ Ethernet.................................................................................................................................. 17

IRQs........................................................................................................................................ 17

Status LEDs........................................................................................................................... 18

Ethernet Drivers.................................................................................................................... 18

≡ Technical assistance .............................................................................................................. 18

5445/5445E Video / Ethernet technical data...............................................................................19

≡ Technical specifications ......................................................................................................... 19

Power requirements ........................................................................................................... 19

Environmental specifications ............................................................................................ 19

Size ...................................................................................................................................... 19

Interface .............................................................................................................................. 19

ROM BIOS .......................................................................................................................... 19

Video memory ..................................................................................................................... 19

Monitor type ....................................................................................................................... 19

Flat panel............................................................................................................................ 19

Mating connectors .............................................................................................................. 20

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≡ Maps ....................................................................................................................................... 20

≡ Interrupts ............................................................................................................................... 21

≡ Jumper settings ..................................................................................................................... 21

≡ Connector pinouts .................................................................................................................. 23

Warranty........................................................................................................................................26

Limitations on warranty ....................................................................................................... 26

Service policy ......................................................................................................................... 27

Returning a product for repair ............................................................................................. 27

Returns................................................................................................................................... 28

Governing law........................................................................................................................ 28

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List of Figures

Figure 2–1 5445/5445E card component diagram................................................................11

Figure 2–2 Edge connector orientation.................................................................................12

Figure 2–3 Populated Micro PC card cage ...........................................................................12

List of Tables

Table 2–1 W4 – +3V / +5V flat panel interface voltage select ...........................................14

Table 2–2 W1 – BIOS enable/disable jumper .....................................................................16

Table 2–3 W8 – Ethernet IRQ select jumper......................................................................17

Table 2–4 Ethernet LEDs ....................................................................................................18

Table A–1 5445 I/O map .......................................................................................................20

Table A–2 5445 memory map...............................................................................................20

Table A–3 5445 video interrupts..........................................................................................21

Table A–4 5445 Ethernet interrupts ...................................................................................21

Table A–5 W1 – BIOS enable/disable jumper .....................................................................21

Table A–6 W2, W3, W11 and W12 – LCD bias polarity select..........................................21

Table A–7 W4 – +3V / +5V flat panel interface voltage select ...........................................22

Table A–8 W5 – SHIFTCLK polarity select ........................................................................22

Table A–9 W6 – 5V or 12V safe select .................................................................................22

Table A–10 W7 – Video IRQ select jumper ...........................................................................22

Table A–11 W8 – Ethernet IRQ select jumper......................................................................22

Table A–12 W10 – LCD bias2 select .....................................................................................23

Table A–13 J2 – CRT connector .............................................................................................23

Table A–14 J10 – Ethernet connector....................................................................................24

Table A–15 J1 – Flat panel connector ...................................................................................24

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