Octagon PC-500 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
PC-500 User’s Manual
5170 (0403)
DiskOnChip® is a registered trademark of M-Systems. Micro PC™, PC SmartLink™,
Octagon Systems Corporation
of Octagon Systems Corporation. QuickBASIC
Corporation. QNX
®
is a registered trademark of QNX Software Systems Ltd.
®
, the Octagon logo and the Micro PC logo are trademarks
®
is a registered trademark of Microsoft
ROM-DOS™ is a trademark of Datalight. Windows™ and Windows NT™ are trademarks of Microsoft Corporation. PICO FA™ is a trademark of Phoenix Technologies
Ltd.
Copyright 1997, 1998, 2003—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.
Technical support: 303-426-4521
Telephone: 303-430-1500
Web site: www.octagonsystems.com
FAX: 303-426-8126
PC-500 user’s manual Notice to user
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 customerinduced, 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.
n 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.
n 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.
n 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.
Notice to user PC-500 user’s manual
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.
n Multiple component failures - The chance of a random compo-
nent 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
found a single case where multiple IC failures were not caused by
misuse or accident. It is very probable that multiple component
failures indicate that they were user-induced.
n Testing “dead” cards - For a card that is “completely nonfunc-
tional”, 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.
n 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.
n 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.
n 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.
n 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.
PC-500 user’s manual Notice to user
n Hot insertion - Plugging cards into the card cage with the power on
will usually not cause a problem. (Octagon urges that you do not
do this!) However, the card may be damaged if the right sequence
of pins contacts as the card is pushed into the socket. This usually
damages bus driver chips and they may become hot when the power
is applied. This is one of the most common failures of expansion
cards.
n Terminated backplanes - Some customers try to use Micro PC
cards in backplanes that have resistor/capacitor termination networks. CMOS cards cannot be used with termination networks.
Generally, the cards will function erratically or the bus drivers may
fail due to excessive output currents.
n 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.
≡ Avoiding damage to the heatsink/CPU
WARNING!
When handling any Octagon CPU card, extreme care must be
taken not to strike the heatsink against another object, such
as a table edge. Also, be careful not to drop the CPU card,
since this may cause damage to the heatsink/CPU as well.
Epoxy adhesive bonds the heatsink to the CPU chip. When
the heatsink is struck, the epoxy adhesive does not allow the
heatsink to separate from the chip. The force of the blow to
the heatsink then causes the legs of the CPU chip to separate
from the PCB. This force damages both the CPU chip and
the PCB.
Note Any physical damage to the CPU control card is not covered under
warranty.
Notice to user PC-500 user’s manual
PC-500 user’s manual Contents
Contents
Abbreviations and terms used in this manual ............................................ xiii
Conventions used in this manual .....................................................................xv
About this manual
Overview: Section 1 – Installation
Chapter 1: Overview ........................................................................................... 1-1
Description.......................................................................................................1-1
PC-500 major hardware features ..................................................................1-1
CPU .........................................................................................................1-1
Up to 48 MB DRAM...............................................................................1-1
Solid-state disks .....................................................................................1-2
Serial ports protected against ESD ......................................................1-3
Local bus SVGA, flat panel interface, and GUI accelerator ...............1-3
Adjustable display bias supply .............................................................1-3
Industrial I/O using EZ I/O...................................................................1-4
Speaker, keyboard, and mouse ports ....................................................1-4
PC/104 16-bit interface..........................................................................1-4
Ethernet..................................................................................................1-4
SCSI ........................................................................................................1-4
PC-500 major software features ....................................................................1-5
Advanced power management and system management input ........1-5
Diagnostic software verifies system integrity automatically .............1-5
SETUP information stored in EEPROM for high reliability..............1-5
Phoenix BIOS .........................................................................................1-6
“Instant DOS” operating system ..........................................................1-6
Programmable video BIOS....................................................................1-6
On-board flash file system.....................................................................1-6
Octagon BIOS extensions......................................................................1-6
Interrupt routing: In system and programmable...............................1-6
Floppy and hard disk ports ...................................................................1-6
Boot sequence .........................................................................................1-7
Multifunctional printer port..................................................................1-7
Watchdog timer added for safety ..........................................................1-7
Real time calendar/clock with battery-backup ....................................1-7
I/O connectors.........................................................................................1-7
Keypad and LCD display support for low cost operator interface .....1-7
Hardware reset.......................................................................................1-8
5 Volt operation lowers system cost......................................................1-8
Rugged environmental operation .........................................................1-8
Size ..........................................................................................................1-8
Chapter 2: Quick start ....................................................................................... 2-1
Installing the PC-500 .....................................................................................2-1
Reference designators.....................................................................................2-6
PC-500 power supply requirements ..............................................................2-8
Running a demo program...............................................................................2-9
Logon message .......................................................................................2-9
What’s next....................................................................................................2-10
iii
Contents PC-500 user’s manual
Chapter 3: SETUP programs ............................................................................ 3-1
Introduction.....................................................................................................3-1
SETUP .............................................................................................................3-1
Running SETUP over the console port ................................................3-4
SETUP example.....................................................................................3-8
SETSSD ...........................................................................................................3-9
PMISETUP......................................................................................................3-9
SETIRQ.EXE...................................................................................................3-9
Chapter 4: Save and run programs ................................................................ 4-1
Save and run your programs on the PC-500 ................................................4-1
Saving programs and support files................................................................4-1
Adding your application ........................................................................4-2
Autoexecuting your application ............................................................4-2
Overriding the autoexecution of your application...............................4-2
Overview: Section 2 – Hardware
Chapter 5: Serial ports....................................................................................... 5-1
Description.......................................................................................................5-1
Serial port options...........................................................................................5-1
Description of serial ports ..............................................................................5-2
Conflicting COM port addresses ...........................................................5-2
COM1 ......................................................................................................5-2
COM2 ......................................................................................................5-3
COM3 through COM5 interrupt/status port .......................................5-3
COM3 ......................................................................................................5-5
COM4 ......................................................................................................5-5
COM5 ......................................................................................................5-6
Null modem cable ...........................................................................................5-6
Mating receptacle...................................................................................5-6
Building your own cable ........................................................................5-7
Function and use of serial ports ....................................................................5-9
COM1 as serial console device ..............................................................5-9
COM1 through COM4 as RS-232 I/O...................................................5-9
COM5 as RS-485 transmitter control ..................................................5-9
RS-485 network.............................................................................................5-10
iv
Chapter 6: LPT1 parallel port .......................................................................... 6-1
LPT1 parallel port ..........................................................................................6-1
Printer..............................................................................................................6-1
Installing a printer ................................................................................6-1
Display .............................................................................................................6-2
Installing a display ................................................................................6-2
Keypad .............................................................................................................6-2
Installing a keypad ................................................................................6-2
Opto rack .........................................................................................................6-3
Chapter 7: Console devices ............................................................................... 7-1
Description.......................................................................................................7-1
Selecting console devices ................................................................................7-1
Local bus SVGA .....................................................................................7-1
Serial console..........................................................................................7-1
Keyboard.................................................................................................7-3
PC-500 user’s manual Contents
Speaker ...................................................................................................7-3
Mouse ......................................................................................................7-3
Enabling/disabling the video BIOS ...............................................................7-3
Re-establishing communications when the console is not working ...7-5
Chapter 8: SSDs, DRAM, and battery backup ............................................. 8-1
Description.......................................................................................................8-1
SSD0 (optional) ...............................................................................................8-1
Selecting SSD0 device type ...................................................................8-1
SSD0 replaced with an SRAM device............................................................8-1
SSD0 replaced with a flash device.................................................................8-2
Selecting an SSD BIOS .........................................................................8-2
SSD0 replaced with an EPROM/OTPROM .........................................8-3
SSD1.................................................................................................................8-3
DRAM...............................................................................................................8-3
Battery backup for SSD0 SRAM and real time calendar clock...................8-4
Installing an AT battery........................................................................8-4
Chapter 9: External drives................................................................................ 9-1
Description.......................................................................................................9-1
Floppy disk controller .....................................................................................9-1
Power requirements...............................................................................9-1
Installing a floppy disk drive ................................................................9-1
Hard disk controller ........................................................................................9-2
Booting with ROM-DOS .................................................................................9-2
Chapter 10: IRQ routing and opto IRQs......................................................10-1
Interrupt routing...........................................................................................10-1
Opto IRQs ......................................................................................................10-3
Interrupt routing matrix defaults ...............................................................10-3
Programming.................................................................................................10-3
Master disable ...............................................................................................10-4
Chapter 11: EZ I/O .............................................................................................11-1
Description.....................................................................................................11-1
Pulling the I/O lines high or low..................................................................11-2
Organization of ports ....................................................................................11-2
Port addressing ....................................................................................11-3
Base I/O address ..................................................................................11-3
Configuring and programming the EZ I/O ports........................................11-4
Programming the EZ I/O.....................................................................11-4
Configuring the EZ I/O ........................................................................11-4
Writing and reading from EZ I/O .......................................................11-5
EZ I/O output program examples .......................................................11-5
EZ I/O input program examples .........................................................11-6
Enhanced INT 17h function definitions......................................................11-6
Initialize EZ I/O ...................................................................................11-6
Write EZ I/O .........................................................................................11-7
Read EZ I/O ..........................................................................................11-8
Opto-module rack interface..........................................................................11-9
Interfacing to switches and other devices.................................................11-11
Chapter 12: LED signaling and “beep” codes ............................................12-1
Description.....................................................................................................12-1
v
Contents PC-500 user’s manual
Chapter 13: CRTs and flat panels .................................................................13-1
Description.....................................................................................................13-1
Video features................................................................................................13-1
Video options .................................................................................................13-1
Programming the video BIOS......................................................................13-2
Connecting the monitor/display...................................................................13-4
Analog monitor.....................................................................................13-4
Flat panel display ................................................................................13-5
Flat panels requiring bias voltage......................................................13-5
LCD bias control examples ........................................................13-6
LCD bias control examples ........................................................13-7
Flat panel considerations .............................................................................13-7
Flat panel interface voltage select: W8 .............................................13-7
Inverted shift clock signal voltage level select: W9 ..........................13-7
Chapter 14: PC/104 expansion........................................................................14-1
Description.....................................................................................................14-1
Chapter 15: SCSI................................................................................................15-1
Description.....................................................................................................15-1
Reprogramming the video BIOS..................................................................15-1
Chapter 16: Ethernet ........................................................................................16-1
Description.....................................................................................................16-1
Overview: Section 3 – System management
Chapter 17: Watchdog timer and hardware reset ....................................17-1
Description.....................................................................................................17-1
Enhanced INT 17h function definitions......................................................17-1
Enable watchdog ..................................................................................17-1
Strobe watchdog...................................................................................17-2
Disable watchdog .................................................................................17-2
Hardware reset..............................................................................................17-3
Chapter 18: Serial EEPROM and CMOS RAM ...........................................18-1
Description.....................................................................................................18-1
Enhanced INT 17h function definitions......................................................18-1
Serial EEPROM ............................................................................................18-1
Read a single word from the serial EEPROM ...................................18-1
Write a single word to the serial EEPROM.......................................18-2
Read multiple words from the serial EEPROM ................................18-3
Write multiple words to the serial EEPROM ....................................18-4
Return serial EEPROM size................................................................18-4
CMOS RAM ...................................................................................................18-5
Read extended CMOS RAM ................................................................18-5
Write extended CMOS RAM ...............................................................18-6
Check CMOS battery...........................................................................18-7
Copy contents of serial EEPROM to extended CMOS RAM ............18-7
Copy contents of extended CMOS RAM to serial EEPROM ............18-8
vi
Chapter 19: Transferring files/remote disks ..............................................19-1
Transferring files between the PC-500 and your PC.................................19-1
Transferring files to the PC-500 ..................................................................19-2
PC-500 user’s manual Contents
Transferring files from the PC-500 .............................................................19-2
Downloading files to the PC-500 using PC SmartLINK ...........................19-3
Remote disks..................................................................................................19-5
Downloading files to the PC-500 using REMDISK/REMSERV.......19-5
PC-500 with one serial cable......................................................19-5
Chapter 20: Managing SSDs ...........................................................................20-1
PICO FA flash file system ............................................................................20-1
Defining SSDs using SETSSD.....................................................................20-1
Using PFORMAT to format an SSD ...........................................................20-2
Formatting SSD1 .................................................................................20-2
Using SYS to make an SSD bootable..........................................................20-3
Adding operating system startup files (using SYS) ..........................20-3
Changing boot SSD.......................................................................................20-4
Autoexecuting your application ..........................................................20-4
Using SETSSD and TESTRFA to test an SSD...........................................20-4
Making copies of the PC-500 SSD ...............................................................20-5
Programming copies of the PC-500 SSD.....................................................20-5
Programming a new BIOS into SSD1.........................................................20-6
Programming the video BIOS into an SSD ................................................20-6
Chapter 21: User-defined jumper..................................................................21-1
User-defined jumper .....................................................................................21-1
Read jumpers........................................................................................21-1
Chapter 22: CPU power management..........................................................22-1
Description.....................................................................................................22-1
Power management overview ......................................................................22-1
Hardware controlled modes..........................................................................22-2
Device power management ..........................................................................22-2
System power management.........................................................................22-3
How to initiate the SUSPEND/RESUME option ..............................22-4
How to initiate the STANDBY option ................................................22-6
Save to disk....................................................................................................22-7
How to initiate the save to disk option...............................................22-8
Power management configuration...............................................................22-9
Enabling power management .............................................................22-9
System timers.....................................................................................22-10
Doze timer enable and resets............................................................22-10
IDLE timer resets ..............................................................................22-11
RESUME from STANDBY ................................................................22-12
RESUME from SUSPEND................................................................22-13
Remote suspend/resume inputs ........................................................22-13
First Suspend/Resume Pulse: ..................................................22-14
Second Suspend/Resume Pulse:...............................................22-14
External PMI interrupt .....................................................................22-14
Thermal management .......................................................................22-15
Bitblt engine .......................................................................................22-15
PMISETUP..................................................................................................22-16
Chapter 23: Troubleshooting..........................................................................23-1
Technical assistance......................................................................................23-3
vii
Contents PC-500 user’s manual
Overview: Section 4 – Appendices
Appendix A: Technical data............................................................................. A-1
Technical specifications................................................................................. A-1
Jumper settings.............................................................................................. A-6
Connector pinouts .......................................................................................... A-9
Tie wrap holes .............................................................................................. A-18
Appendix B: Software utilities ....................................................................... B-1
Introduction.................................................................................................... B-1
GETBIOS.EXE ............................................................................................... B-2
GETIMG.EXE................................................................................................. B-2
GETIMGH.EXE ............................................................................................. B-3
HIMEM.SYS................................................................................................... B-4
I17HNDLR.EXE............................................................................................. B-5
LCDBIAS.EXE ............................................................................................... B-6
LPT1CON.COM ............................................................................................. B-7
PFORMAT.EXE.............................................................................................. B-7
PGMBIOS.EXE .............................................................................................. B-8
PGMIMG.EXE................................................................................................ B-9
PGMIMGH.EXE........................................................................................... B-10
PGMVIDEO.EXE ......................................................................................... B-11
PHDISK.EXE ............................................................................................... B-12
PICOFA.SYS ................................................................................................ B-13
PMISETUP.EXE .......................................................................................... B-14
REMDISK.EXE............................................................................................ B-15
REMQUIT.COM ........................................................................................... B-17
REMSERV.EXE............................................................................................ B-17
RESET.COM................................................................................................. B-19
SCONSOLE.EXE ......................................................................................... B-19
SETIRQ.EXE................................................................................................ B-20
SETSSD.EXE ............................................................................................... B-20
SETUP.COM................................................................................................. B-22
TESTRFA.EXE............................................................................................. B-23
TRANSFER.EXE ......................................................................................... B-24
VDISK.SYS................................................................................................... B-26
viii
Appendix C: Third party support .................................................................. C-1
Using QNX on the PC-500 ............................................................................ C-1
Programming QNX into SSD1............................................................. C-1
Using M-Systems DiskOnChip (DOC) ......................................................... C-1
Booting from the DOC drive ................................................................ C-2
Appendix D: Accessories .................................................................................. D-1
Warranty
PC-500 user’s manual Contents
List of figures
Figure 2-1 PC-500 component diagram...................................................2-2
Figure 2-2 PC-500 center-to-center hole dimensions..............................2-3
Figure 2-3 Power connector: P8, P9 ........................................................2-4
Figure 5-1 Null modem adapter and VTC-20F cable .............................5-7
Figure 5-2 Custom null modem cable for the PC-500 ............................5-8
Figure 5-3 PC-500 serial devices..............................................................5-9
Figure 5-4 RS-485 two-wire (half duplex) transmission ......................5-11
Figure 6-1 LPT1 as a printer port............................................................6-1
Figure 6-2 LPT1 as a display or keypad port..........................................6-3
Figure 6-3 LPT1 and an opto rack ...........................................................6-3
Figure 7-1 The PC-500 and a serial console............................................7-2
Figure 7-2 VTC-20F cable and null modem adapter ..............................7-2
Figure 7-3 Changing ROM Enable flowchart..........................................7-4
Figure 10-1 Interrupt routing matrix ......................................................10-2
Figure 11-1 Typical EZ I/O configurations ..............................................11-1
Figure 11-2 Organization of ports ............................................................11-3
Figure 11-3 MPB-16PC opto rack hookup ...............................................11-9
Figure 11-4 PC-500 interfacing with an STB-26 terminal board........11-11
Figure 13-1 The PC-500, a VGA monitor, and an AT/PS-2 compatible
keyboard ................................................................................13-3
Figure 13-2 The PC-500 and a VGA monitor ..........................................13-4
Figure 13-3 The PC-500 and a flat panel display ...................................13-5
Figure 14-1 Typical PC/104 module stack...............................................14-1
Figure 19-1 Downloading files using TRANSFER.EXE.........................19-4
Figure B-1 Cabling diagram for a standard cable................................ B-16
ix
Contents PC-500 user’s manual
List of tables
Table 2-1 Power connector: P8, P9 ........................................................2-5
Table 2-2 PC-500 connectors...................................................................2-6
Table 2-3 TTL and RS-485 interface: W1 .............................................2-6
Table 2-4 RS-485 termination select jumper: W1 ................................2-6
Table 2-5 BIOS and boot option jumper: W2........................................2-7
Table 2-6 EZ I/O pull-up/pull-down, user option jumper: W3 .............2-7
Table 2-7 Auxiliary option jumper: W4.................................................2-7
Table 2-8 SSD0 device configuration: W5, W2[7-8]..............................2-8
Table 3-1 PC-500 SETUP parameters ...................................................3-2
Table 5-1 COM port options....................................................................5-1
Table 5-2 Conflicting COM port addresses ............................................5-2
Table 5-3 COM1 available addresses (IRQ 4 dedicated) ......................5-3
Table 5-4 COM2 available addresses (IRQ3 dedicated) .......................5-3
Table 5-5 Register 0A9h..........................................................................5-4
Table 5-6 Reading the interrupt status port: Register 0A9h ..............5-4
Table 5-7 Interrupt status port (138h, 158h, 338h*, and 358h) ..........5-5
Table 5-8 COM3 available address and IRQ routing............................5-5
Table 5-9 COM4 available address and IRQ routing............................5-5
Table 5-10 Available addresses for COM5 (IRQ 5 default, routable) ....5-6
Table 5-11 COM5: J17, RS-485 or TTL interface....................................5-6
Table 5-12 Custom RS-232 null modem cable for the PC-500:
First COM port........................................................................5-7
Table 5-13 Custom RS-232 null modem cable for the PC-500:
Second COM port ....................................................................5-8
Table 5-14 RS-485 transmitter control: COM5 at location 320h........5-10
Table 5-15 RS-485 termination select jumper: W1 ..............................5-10
Table 5-16 RS-485 and TTL interfaces ..................................................5-10
Table 7-1 Video BIOS disabling and enabling options in SETUP
(C0000h-C7FFFh, C8000h-CFFFFh ROM Enable).............7-4
Table 8-1 SSD0 device selection jumpers: W5, W2[7-8]........................8-1
Table 8-2 Selecting an SSD BIOS: W2[5-6] ..........................................8-2
Table 8-3 SSD0 device configuration: W5, W2[7-8]..............................8-4
Table 8-4 Battery connector: J8.............................................................8-4
Table 10-1 Interrupt status port (ISP) map setting
at I/O location 0A9h..............................................................10-4
Table 11-1 EZ I/O connector: J11 ..........................................................11-2
Table 11-2 EZ I/O pull-up/pull-down jumpers: W3 ..............................11-2
Table 11-3 EZ I/O port address...............................................................11-3
Table 11-4 Reading the EZ I/O port .......................................................11-4
Table 11-5 EZ I/O port byte ....................................................................11-5
Table 11-6 EZ I/O opto-rack interface..................................................11-10
Table 12-1 Ethernet LEDs ......................................................................12-1
Table 12-2 Additional error codes for Phoenix BIOS ............................12-4
Table 13-1 Video controller and associated CRT, flat panel,
and PC-video circuitry ..........................................................13-2
Table 13-2 Flat panel interface voltage select: W8 ..............................13-7
Table 13-3 Inverted shift clock signal voltage level select: W9 ...........13-8
Table 16-1 Ethernet LEDs ......................................................................16-1
Table 22-1 Remote suspend/resume: J10............................................22-14
Table 22-2 Enhanced mode, CPU clock speed: W2[3-4] .....................22-16
Table A-1 PC-500 memory map ............................................................. A-3
x
PC-500 user’s manual Contents
Table A-2 PC-500 I/O map...................................................................... A-4
Table A-3 I/O map (Latched registered outputs via OctaGlue:
Address at X0A8h) ................................................................. A-5
Table A-4 I/O map (Configuration inputs via OctaGlue:
Address at X0A9h) ................................................................. A-5
Table A-5 COM1 available addresses.................................................... A-5
Table A-6 COM2 available addresses.................................................... A-6
Table A-7 Available LPT1 port addresses ............................................. A-6
Table A-8 TTL and RS-485 interface: W1 ............................................ A-6
Table A-9 RS-485 termination select jumper: W1 ............................... A-6
Table A-10 BIOS and boot option jumper: W2....................................... A-7
Table A-11 EZ I/O pull-up/pull-down, user option jumper: W3 ............ A-7
Table A-12 Auxiliary option jumper: W4................................................ A-7
Table A-13 SSD0 device configuration: W5............................................ A-8
Table A-14 Flat panel voltage select: W8 ............................................... A-8
Table A-15 Inverted shift clock signal voltage level select: W9 ............ A-8
Table A-16 PC/104 signal assignments: J1 ............................................ A-9
Table A-17 Keyboard connector: J2 ...................................................... A-10
Table A-18 Mouse connector: J3............................................................ A-10
Table A-19 Speaker connector: J4......................................................... A-10
Table A-20 Flat panel connector: J5 ..................................................... A-11
Table A-21 VGA connector: J6............................................................... A-11
Table A-22 PC video connector: J7........................................................ A-12
Table A-23 Battery connector: J8.......................................................... A-12
Table A-24 Ethernet connector: J9........................................................ A-13
Table A-25 OPTOA and OPTOB: J10................................................... A-13
Table A-26 EZ I/O connector: J11 ......................................................... A-13
Table A-27 SCSI connector: J12............................................................ A-14
Table A-28 AT and industrial serial for COM1 and COM2: J13........ A-15
Table A-29 AT and industrial serial for COM3 and COM4: J14........ A-15
Table A-30 Floppy drive connector: J15 ............................................... A-16
Table A-31 LPT1 as printer connector: J16 ......................................... A-16
Table A-32 RS-485 and TTL interfaces for COM5: J17 ...................... A-17
Table A-33 IDE hard rive connector: J18 ............................................. A-17
Table A-34 Power connector: P8, P9 ..................................................... A-18
Table D-1 PC-500 mating connectors ....................................................D-1
Table D-2 Cables and terminal board....................................................D-2
Table D-3 Memory devices......................................................................D-2
Table D-4 LCD displays and keypads....................................................D-3
Table D-5 Opto rack and modules..........................................................D-3
Table D-6 Miscellaneous part numbers .................................................D-3
xi
Contents PC-500 user’s manual
xii
PC-500 user’s manual Abbreviations and terms used in this manual
Abbreviations and terms used in
this manual
Throughout this manual, the following symbols and terms are used:
Autoexecution Automatic execution of a program on powerup or
reset.
BIOS Basic Input Output System. Detailed instructions
that activate peripheral devices. See ROM-DOS.
BIOS drive The solid-state disk which contains the system BIOS
and ROM-DOS.
bpp bits per pixel
Console port Video card or COM1 where BIOS and DOS messages
appear and keyboard input is available.
DRAM Dynamic Random Access Memory devices. DRAMs
provide volatile memory with unlimited read and
write cycles.
Expansion card The expansion cards add I/O functions to the Micro
PC system, such as analog input/output, digital
input/output, motion control, and display.
EZ I/O This digital I/O chip supplies 24 I/O lines which can
be individually programmed as 5V input or 5V
output.
Flash Electrically erasable PROM which allows at least
100,000 write cycles.
h The suffix “h” denotes a hexadecimal number. A
decimal number has no prefix or suffix. For ex-
ample, 1000h and 4096 are equivalent.
KB Kilobyte (1,024 8-bit bytes).
MB Megabyte (1,048,576 8-bit bytes).
Memory device The type of static RAM, DRAM, flash memory, or
EPROM specified for either volatile or nonvolatile
memory.
PC/104 An expansion bus used for holding 8- and 16-bit
expansion expansion cards.
PC SmartLINK A serial communications software package designed
by Octagon for use with the PC-500 single board
computer. Refers to all versions of PC SmartLINK.
xiii
Abbreviations and terms used in this manual PC-500 user’s manual
PC Video A feature on the PC-500 which imports an external
video source into the virtual graphics array (VGA)
system. This feature allows for advanced video
connections including video overlays.
PICO FA Phoenix’s flash file system used to access SSDs from
DOS as a read/write DOS drive.
ROM Read Only Memory devices. ROMs provide nonvola-
tile memory, have a limited number of write cycles,
and include EPROMs and EEPROMs.
ROM-DOS Operating system included in Micro PC ROM.
Single board A printed circuit board that contains a complete
computer computer: CPU, memory, I/O, and clock. The single
board computer controls the operation of all the
expansion cards.
Solid-state disk A simulated disk which uses a high speed solid-state
(SSD) memory device. For example, flash memory,
EEPROM, or static RAM.
Static RAM Static Random Access Memory device. Static RAMs
provide volatile memory with unlimited read and
write cycles. They may be used with a backup
battery.
TTL compatible Transistor transistor logic compatible; 0-5V logic
levels.
Virtual drive A disk created in DOS or extended memory which
emulates an actual disk. The virtual drive provides
temporary storage for files. When power to the
computer is turned off the virtual drive disappears.
W[ - ] Denotes a jumper block and the pins to connect.
XMODEM A communications protocol which allows transfer of
files between two computers.
XON/XOFF A communications protocol for asynchronous connec-
tions. The receiver can pace the sender by sending
the XOFF and XON characters to stop and continue
the data flow.
+5V Safe +5V at the I/O connectors that is protected by a
0.75A fuse.
xiv
PC-500 user’s manual Conventions used in this manual
Conventions used in this manual
This section explains the format used for notes, warnings, and command
entry.
≡ Notes and warnings
Special notes and warnings appear in this manual. Each one has a
different meaning and format. They are as follows:
Note A note is supplementary or background information. At other times, it
is a hint or reminder that makes a task easier or quicker.
WARNING!
A warning gives vital information. Failure to heed a warning may cause system failure, equipment damage, or bodily
harm to the system operator.
≡ Command format and procedures
For some commands, you will only enter a single keyword (for example,
reset). For most commands, however, you will enter several keywords
followed by one or more parameters for which you must supply values.
Commands must be entered in a specific format. To indicate the format,
this manual uses a series of conventions that are explained below. The
conventions cover the rules for issuing all commands, including the most
complex ones. Most commands, however, are much simpler.
The command format looks like this:
command [type_this | or_ this] input {optional_input}
Follow these rules and conventions:
n Information which appears on your screen is shown in a different
type face, for example:
PhoenixBIOS(TM) A486 Version 1.03
Copyright (C) 1985-1994 Phoenix Technologies, Ltd.
All Rights Reserved
Octagon Systems Corp. PC500 CPU
n Commands that you must key in are shown in Courier Bold, for
example:
C:> RESET
xv
Conventions used in this manual PC-500 user’s manual
n Italicized refers to information that is specific to your particular
system or program, e.g.,
Enter filename means enter the name of your file.
n Paired angle brackets are used to indicate a specific key on your
keyboard, e.g., <ESC> means the escape key; <CTRL> means the
control key; <F1> means the F1 function key.
n All addresses are given in hexadecimal, for example, 328h.
xvi
PC-500 user’s manual About this manual
About this manual
The PC-500 user’s manual provides information about installing and
configuring the PC-500. This manual is divided into four sections:
n Section 1 – Installation
Chapter 1: Overview
Chapter 2: Quick start
Chapter 3: SETUP programs
Chapter 4: Save and run programs
n Section 2 – Hardware
Chapter 5: Serial ports
Chapter 6: LPT1 parallel port
Chapter 7: Console devices
Chapter 8: SSDs, DRAM, and battery backup
Chapter 9: External drives
Chapter 10: IRQ routing and opto IRQs
Chapter 11: EZ I/O
Chapter 12: LED signaling and “beep” codes
Chapter 13: CRTs and flat panels
Chapter 14: PC/104 expansion
Chapter 15: SCSI
Chapter 16: Ethernet
n Section 3 – System management
Chapter 17: Watchdog timer and hardware reset
Chapter 18: Serial EEPROM and CMOS RAM
Chapter 19: Transferring files/remote disks
Chapter 20: Managing SSDs
Chapter 21: User-defined jumper
Chapter 22: CPU power management
Chapter 23: Troubleshooting
n Section 4 – Appendices
Appendix A: Technical data
Appendix B: Software utilities
Appendix C: Third party support
Appendix D: Accessories
About this manual PC-500 user’s manual
PC-500 user’s manual Overview of Section 1
Overview: Section 1 – Installation
Section 1 provides installation and programming instructions, startup
options, and system configuration program examples. The following
chapters are included:
Chapter 1: Overview
Chapter 2: Quick start
Chapter 3: SETUP programs
Chapter 4: Save and run programs
Overview of Section 1 PC-500 user’s manual
PC-500 user’s manual Overview
Chapter 1: Overview
≡ Description
The PC-500 Mobile Industrial Computer™ (MIC) is a high performance,
single board PC in Octagon’s semi-custom product line. The PC-500
integrates serial communication, industrial digital I/O, a floppy and
local bus hard disk port, a multifunctional parallel port, and a local bus
video which supports monitors and flat panels. This single board computer has an interrupt routing matrix, two solid-state disks, a PC/104
interface, a SCSI-2 interface host port, and a 10Base-T Ethernet port.
The PC-500 also supports various CPU types including 586/133 MHz
and can have up to 16 MB of on-board DRAM with an expansion of
48 MB by adding a 32 MB DIMM module. This board is supplied with
DOS 6.22 in ROM but will also execute other operating systems such as
Windows™, Windows NT™, and QNX
same functional blocks as the Micro PC™, the circuitry has been fully
proven as reliable and the software is compatible with the software in
the Micro PC series.
®
. Since the PC-500 uses the
Specified to your engineering needs, the PC-500 can be ordered as a
semi-custom board in OEM quantities. The stocked version of the
PC-500 is listed below with the standard and optional features. The
standard version can be used for system development and an optional
version of the PC-500 is usually application specific.
≡ PC-500 major hardware features
CPU
The high performance 586 CPU comes in two versions. One version is a
120MHz586 and the other is a 133MHz586. Both versions operate at
3.3V for low power consumption. The PC-500 has a local bus speed of
33 MHz and an ISA bus speed of 8.33 MHz.
Up to 48 MB DRAM
The standard unit is supplied with 1 MB of fast, EDO surface mount
DRAM. The use of EDO DRAM increases performance by 20% which, in
most cases, eliminates the need for an expensive L2 cache. The PC-500
can contain up to 16 MB of on-board DRAM. Up to 32 MB of additional
DRAM can be added through an optional DIMM module, which makes a
total of 48 MB DRAM. Two holes are on-board the PC-500 to secure the
DIMM module in high vibration environments. All surface mount
1-1
Overview PC-500 user’s manual
DRAM and DIMM modules from Octagon meet the full PC-500 temperature range. Customers who need a 0° to 70°C range can install
commercially available DIMM modules onto the PC-500.
n 1 MB EDO surface mount standard
n 16 MB EDO surface mount optional
n SO-DIMM socket installed standard
n SO-DIMM socket not installed optional
Solid-state disks
SSD0
A 32-pin DIP socket accepts either a 5V flash, SRAM, or 512 KB/1 MB
EPROM. The socket exhibits high retention force and affords a gas
tight contact. SSD0 optionally contains the BIOS drive and ROM-DOS
6.22 in ROM. By default, the optional SSD0 contains a 192 KB backup
BIOS with a 320 KB or a 512 KB drive area. Flash file system software
is included which allows the SSDs to emulate hard disk operation.
SSD0 options include:
n SSD0 socket installed standard
n SSD0 socket not installed optional
n SSD0 socket/EPROM installed optional
For information on changing the device type, refer to the W5 SSD0
table in the Quick start chapter. You can also install compatible
PROMs into SSD0 through the supplied utility programs found on the
PC-500 utility disk. You can format the flash while in the socket.
EPROM usage, however, requires off-card programming from either a
master flash or a master EPROM.
SSD0 also supports a battery back up voltage. The PC-500 is capable of
supplying a battery voltage to SSD0 with SRAM installed.
SSD1
SSD1 is used for storage of the applications program. A standard 2 MB
5V flash is soldered on-card. The flash programmer is built-in which
allows on-card programming of the device. The PC-500 includes flash
file system software, which permits the SSDs to emulate hard disk
operation. Automatic “wear leveling” ensures that no single section of a
chip will reach its life span (100,000 times), while other sections will
scarcely be used. A 1 MB device reserves 192 KB for BIOS and 832 KB
for a drive area, a 2 MB device reserves 192 KB for BIOS and 1856 KB
for a drive area.
1-2
n 2 MB EPROM standard
n 1 MB EPROM optional
n SSD1 not installed optional
PC-500 user’s manual Overview
Serial ports protected against ESD
The PC-500 can have either two or five serial ports. All five serial ports
are standard, while COM3 through COM5 can be optionally omitted
from the PC-500. COM1 through COM4 are RS-232 and have the full
8-wire PC signal or they can optionally have 4-wire industrial RS-232
serial port lines. The 4-wire industrial RS-232 lines support RxD, TxD,
RTS, CTS and the DTR pin with a 1K pull-up to 5V. The interface to
COM5 is 2-wire industrial RS-485 also configurable to 2-wire TTL.
COM1 through COM5 have the following specifications:
n IEC1000, level 3, ESD protection specification
— Contact discharge ±6 kV
— Air-gap discharge ±8 kV
n Backdrive protection
n 16C550 compatible
n Up to 115.2K baud
n 16 byte FIFO buffers
n RS-232 voltages generated on-card
n COM1 through COM5 standard
n Omission of COM3 through COM5 optional
Local bus SVGA, flat panel interface, and GUI accelerator
The video system on the PC-500 uses the advanced 65550 video chip
from Chips & Technologies. It supports CRT, LCD and EL displays
with resolutions to 1024 x 768 bpp. Displays from CGA through SVGA
are supported. The 65550 is also a graphics accelerator with real time
PC-video being supported. Since the video circuitry operates on the
local bus at the full processor speed, programs like Windows execute
very rapidly. The video section has 2 MB of video RAM for high resolution displays and simultaneous CRT and flat panel operation.
The PC-500 supports both 3.3V and 5V flat panel displays. It has a 12V
connector for powering the backlighting on the displays and a 3.3V at
100mA connector to power the newer generation displays that use 3.3V
logic.
n Local bus flat panel video present standard
n No local bus flat panel video present optional
Adjustable display bias supply
An on-board voltage converter eliminates the need for a separate bias
supply for the LCD contrast control. The on-board power converter is
factory configurable and can be made to be compatible with most LCD
displays. The standard default range for the power converter is from
+23V to +29V.
n + Bias voltage 23V to 29V standard
n – Bias voltage/other range optional
n No bias supply optional
1-3
Overview PC-500 user’s manual
Industrial I/O using EZ I/O
The PC-500 is supplied with 24 lines of industrial I/O, using the Octagon EZ I/O digital I/O chip. Each EZ I/O line is programmable as an
input or output. The lines are 5V compatible and can sink and source
15mA. The EZ I/O port can drive the Octagon MPB series opto-isolation
module (Opto 22, G4 style) racks directly, controlling AC and DC loads
to 240V at 3A.
Speaker, keyboard, and mouse ports
The speaker connector is PC compatible and is a standard feature. The
keyboard controller accepts an AT style keyboard and has a PS-2 type
connector. The keyboard port is standard. The mouse port is optional
and conforms to the PS-2 standard. Neither the keyboard nor the
mouse are required for operation.
n Mouse port included standard
n Mouse port not included optional
PC/104 16-bit interface
This interface is a standard feature on the PC-500 and accepts an 8- or
a 16-bit PC/104 expansion board. PC/104 expansion boards are available from several manufacturers. As many as three PC/104 expansion
boards may be stacked on the PC-500.
Ethernet
The PC-500 provides a 10Base-T Ethernet port, located at J9. This
interface is a standard feature on the PC-500 and supports the IEEE
802.3 Ethernet standard. The Ethernet controller IC chip provides the
following:
n 16-bit ISA interface
n 4 KB on chip buffer
n Integrated 10 Base-T transceiver interface
n Four LEDs for status and diagnostic purposes
The PC-500 Ethernet interface supports the 10Base-T physical interface. This port operates at 10 MHz and uses twisted-pair wiring cable,
which is built in a star configuration. The 10Base-T physical interface
terminates at the standard, 8-position RJ-45, latching phone jack and is
vertically accessed.
1-4
SCSI
The PC-500 has a SCSI-2 host interface, located at J12. This device is a
16-bit ISA bus compatible part and has a sustained data rate of 10 MB
per second in the fast SCSI-2 synchronous transfer mode. It also has
parity generation and checking, noise filters, a low power mode, and ISA
bus RAM buffers.
PC-500 user’s manual Overview
n SCSI-2 host interface, included standard
n SCSI-2 host interface, not included optional
≡ PC-500 major software features
Advanced power management and system management
input
Power management can be used to reduce power consumption or to
freeze the state of the program on the occurrence of a power management interrupt. Power consumption can be reduced by more than 60%.
This reduces the heat load and extends the battery life in mobile applications. There are opto-isolated system management and suspend/
resume inputs with 4-6V ranges. A system management input (SMI)
will cause the PC-500 to save its current status. When the system is
signaled to restart, execution resumes at the point the system last
stopped. The following are functions in the advanced power management and SMI:
n Suspend/resume by SMI input and software — halts CPU
n Wake up through various interrupts including keyboard, SMI
and serial port
n Slow CPU by dividing clock
n Contextual save to disk.
Diagnostic software verifies system integrity automatically
The PC-500 has built-in diagnostic software that can be used to verify
on-card I/O and memory functions. On powerup, a series of tests is
performed. If a problem occurs, the failed test can be identified by the
color sequence on an on-board, bicolored LED. The test is performed
automatically every time the system is reset or powered up. Software,
test equipment, monitor, keyboard, disks, or test fixtures are not required for memory verification. See the LED signaling “beep” codes
chapter for a complete listing of tests and failures and their descriptions.
SETUP information stored in EEPROM for high reliability
Loss of SETUP data is serious in industrial applications. Most PCs
store SETUP information in battery-backed CMOS RAM. If the battery
fails or is replaced during routine maintenance, this information is lost.
Without a keyboard and monitor in embedded applications, time consuming re-initialization is required. The PC-500 stores the SETUP
information in EEPROM with 1,536 bytes available to the user. Software routines to use this available memory come with the PC-500.
1-5
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