Octagon PC-510 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-510 User’s Manual

5171 (0505)

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, 2004, 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.

Technical Support: 303-426-4521

Telephone: 303-430-1500

Web site:

FAX: 303-426-8126

www.octagonsystems.com

PC-510 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-510 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 found a single case where multiple IC failures were

never

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-510 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 physical 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-510 user’s manual

PC-510 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-510 major hardware features................................................................. 1-1

CPU....................................................................................................... 1-1

Up to 48 MB DRAM ............................................................................. 1-1

Solid-state disks ................................................................................... 1-2

SSD0 ............................................................................................ 1-2

SSD1 ............................................................................................ 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

PC-510 major software features .................................................................. 1-4

Advanced power management and system management input ....... 1-4

Diagnostic software verifies system integrity automatically ............ 1-5

SETUP information stored in EEPROM for high reliability............. 1-5

Phoenix BIOS....................................................................................... 1-5

“Instant DOS” operating system......................................................... 1 -5

Programmable video BIOS.................................................................. 1- 5

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 ....................................................................................... 1-6

Multifunctional printer port ................................................................ 1-6

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..................................................................................... 1-7

5 Volt operation lowers system cost .................................................... 1-7

Rugged environmental operation........................................................ 1- 8

Size........................................................................................................ 1-8

Chapter 2: Quick start ..................................................................................... 2-1

Installing the PC-510 ................................................................................... 2-1

Reference designators................................................................................... 2-6

PC-510 power supply requirements............................................................. 2- 8

Running a demo program............................................................................. 2-9

Logon message ..................................................................................... 2-9

What’s next.................................................................................................. 2-11

iii

Contents PC-510 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-510............................................... 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.............................. 4-3

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 COM6 interrupt/status port ...................................... 5-3

COM3.................................................................................................... 5-5

COM4.................................................................................................... 5-5

COM5.................................................................................................... 5-5

COM6.................................................................................................... 5-6

Null modem cable ......................................................................................... 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 COM6 as RS-232 I/O ................................................. 5-9

COM5 as GPS I/O ................................................................................ 5- 9

COM6 RS-485 transmitter control.................................................... 5-10

RS-485 network........................................................................................... 5-11

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

PC-510 user’s manual Contents

Keyboard .............................................................................................. 7-3

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

Installing a hard drive......................................................................... 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

EZ I/O options ............................................................................................. 11-2

Pulling the I/O lines high or low ................................................................ 11-2

Organization of ports .................................................................................. 11-3

Port addressing .................................................................................. 11-4

Base I/O address ................................................................................ 11-4

Configuring and programming the EZ I/O ports ...................................... 11-4

Programming the EZ I/O ................................................................... 11-5

Configuring the EZ I/O ...................................................................... 11-5

Writing and reading from EZ I/O...................................................... 11-6

EZ I/O output program examples ..................................................... 11-6

EZ I/O input program examples........................................................ 11-6

Enhanced INT 17h function definitions .................................................... 11-7

Initialize EZ I/O 1 .............................................................................. 11-7

Write EZ I/O 1 .................................................................................... 11-8

Read EZ I/O 1..................................................................................... 11-8

Initialize EZ I/O 2 .............................................................................. 11-9

Write EZ I/O 2 .................................................................................. 11-10

Contents PC-510 user’s manual

Read EZ I/O 2 ................................................................................... 11-11

Opto-module rack interface ...................................................................... 11-11

Interfacing to switches and other devices ............................................... 11-13

Chapter 12: LED signaling and “beep” codes........................................... 12-1

Description .................................................................................................. 12-1

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 .................................................... 13-6

LCD bias control examples....................................................... 13-6

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: GPS interface ............................................................................ 14-1

Description .................................................................................................. 14-1

Mounting the GPS module to the PC-510 ................................................. 14-2

GPS interface port options ......................................................................... 14-3

Routing the GPS data........................................................................ 14-3

Chapter 15: PC/104 expansion...................................................................... 15-1

Description .................................................................................................. 15-1

Overview: Section 3 – System management

Chapter 16: Watchdog timer and hardware reset ................................... 16-1

Description .................................................................................................. 16-1

Enhanced INT 17h function definitions .................................................... 16-1

Enable watchdog ................................................................................ 16-1

Strobe watchdog................................................................................. 16-2

Disable watchdog ............................................................................... 16-2

Hardware reset ........................................................................................... 16-3

Chapter 17: Serial EEPROM and CMOS RAM.......................................... 17-1

Description .................................................................................................. 17-1

Enhanced INT 17h function definitions .................................................... 17-1

Serial EEPROM .......................................................................................... 17-1

Read a single word from the serial EEPROM .................................. 17-1

Write a single word to the serial EEPROM...................................... 17-2

Read multiple words from the serial EEPROM ............................... 17-3

Write multiple words to the serial EEPROM................................... 17-4

Return serial EEPROM size.............................................................. 17-4

CMOS RAM................................................................................................. 17-5

Read extended CMOS RAM .............................................................. 17-5

Write extended CMOS RAM ............................................................. 17-6

Check CMOS battery ......................................................................... 17-7

Copy contents of serial EEPROM to extended CMOS RAM ........... 17-7

Copy contents of extended CMOS RAM to serial EEPROM ........... 17-8

PC-510 user’s manual Contents

Chapter 18: Transferring files/remote disks............................................. 18-1

Transferring files between the PC-510 and your PC................................ 18-1

Transferring files to the PC-510 ................................................................ 18-2

Transferring files from the PC-510............................................................ 18-2

Downloading files to the PC-510 using PC SmartLINK .......................... 18-3

Remote disks ............................................................................................... 18-5

Downloading files to the PC-510 using REMDISK/REMSERV ...... 18-5

PC-510 with one serial cable .................................................... 18-5

Chapter 19: Managing SSDs ......................................................................... 19-1

PICO FA flash file system .......................................................................... 19-1

Defining SSDs using SETSSD ................................................................... 19-1

Using PFORMAT to format an SSD.......................................................... 19-3

Formatting SSD1 ............................................................................... 19-3

Using SYS to make an SSD bootable ........................................................ 19-3

Adding operating system startup files (using SYS) ......................... 19-3

Changing boot SSD..................................................................................... 19-4

Autoexecuting your application......................................................... 19-4

Using SETSSD and TESTRFA to test an SSD ......................................... 19-4

Making copies of the PC-510 SSD ............................................................. 19-5

Programming copies of the PC-510 SSD ................................................... 19-5

Programming a new BIOS into SSD1 ....................................................... 19-6

Programming the video BIOS into an SSD............................................... 19-6

Chapter 20: User-defined jumper ................................................................ 20-1

User-defined jumper ................................................................................... 20-1

Read jumpers...................................................................................... 20-1

Chapter 21: CPU power management ........................................................ 21-1

Description .................................................................................................. 21-1

Power management overview .................................................................... 21-1

Hardware controlled modes........................................................................ 21-2

Device power management ........................................................................ 21-2

System power management ....................................................................... 21-3

How to initiate the SUSPEND/RESUME option ............................. 21-4

How to initiate the STANDBY option............................................... 21-6

Save to disk ................................................................................................. 21-7

How to initiate the save to disk option ............................................. 21-8

Power management configuration............................................................. 21-9

Enabling power management ........................................................... 21-9

System timers................................................................................... 21-10

Doze timer enable and resets .......................................................... 21-10

IDLE timer resets ............................................................................ 21-11

RESUME from STANDBY .............................................................. 21-12

RESUME from SUSPEND .............................................................. 21-13

Remote suspend/resume inputs ...................................................... 21-13

First Suspend/Resume Pulse:................................................. 21-14

Second Suspend/Resume Pulse: ............................................. 21-14

External PMI interrupt ................................................................... 21-14

Thermal management ..................................................................... 21-15

Bitblt engine ..................................................................................... 21-15

PMISETUP................................................................................................ 21-16

vii

Contents PC-510 user’s manual

Chapter 22: Troubleshooting........................................................................ 22-1

Technical assistance.................................................................................... 22-3

Overview: Section 4 – Appendices

Appendix A: Technical data ............................................................................A-1

Technical specifications ................................................................................A-1

Jumper settings ............................................................................................ A-5

Connector pinouts .........................................................................................A-8

Tie wrap holes ............................................................................................. A-19

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-8

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-510............................................................................ 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-510 user’s manual Contents

List of figures

Figure 2-1 PC-510 component diagram ................................................. 2- 2

Figure 2-2 PC-510 center-to-center hole dimensions............................. 2-3

Figure 2-3 Power connector: P8, P9....................................................... 2 -4

Figure 2-4 PC-510, keyboard, and monitor ............................................ 2-5

Figure 5-1 Null modem adapter and VTC-20F cable ............................ 5 - 7

Figure 5-2 Custom null modem cable for the PC-510 ........................... 5-8

Figure 5-3 PC-510 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-510 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............................................ 11-12

Figure 11-4 PC-510 interfacing with an STB-26 terminal board....... 11-14

Figure 13-1 The PC-510, a VGA monitor, and an AT/PS/2

compatible keyboard ........................................................... 13-3

Figure 13-2 The PC-510 and a VGA monitor......................................... 13-4

Figure 13-3 The PC-510 and a flat panel display.................................. 13-5

Figure 15-1 Typical PC/104 expansion module stack............................ 15-1

Figure 18-1 Downloading files using TRANSFER.EXE........................ 18-4

Figure 18-2 Downloading files to the PC-510 with one serial cable

using REMDISK/REMSERV .............................................. 18-6

Figure B-1 Cabling diagram for a standard cable................................ B-16

Contents PC-510 user’s manual

List of tables

Table 2-1 Power connector: P8, P9....................................................... 2-5

Table 2-2 PC-510 connectors ................................................................. 2-6

Table 2-3 RS-485 termination select jumper: W1............................... 2-6

Table 2-4 BIOS and boot option jumper: W2....................................... 2-7

Table 2-5 Auxiliary option jumper: W3................................................ 2-7

Table 2-6 EZ I/O pull-up/pull-down, user option jumper: W4 ............ 2-7

Table 2-7 SSD0 device selection jumpers: W5, W2[7-8]....................... 2-8

Table 2-8 Jupiter module antenna voltage select: W6........................ 2 - 8

Table 2-9 Flat panel interface voltage select: W8............................... 2 -8

Table 2-10 Inverted shift clock signal voltage level select: W9 ............ 2-8

Table 3-1 PC-510 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 (IRQ4 dedicated) ...................... 5 - 2

Table 5-4 COM2 available addresses (IRQ3 dedicated) ...................... 5 - 3

Table 5-5 Register 0A9h ........................................................................ 5-3

Table 5-6 Reading the interrupt status port: Register 0A9h ............. 5-4

Table 5-7 Interrupt status port (138h, 158h, 338h, and 358h) ........... 5- 4

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 at port 0A9h

(IRQ 15 default, routable)..................................................... 5-6

Table 5-11 Available addresses for COM6 at port 0A9h

(IRQ 15 default, routable)..................................................... 5-6

Table 5-12 Custom RS-232 null modem cable for the PC-510:

First COM port ...................................................................... 5-7

Table 5-13 Custom RS-232 null modem cable for the PC-510:

Second COM port................................................................... 5-8

Table 5-14 RS-485 transmitter control: COM6 at location 32Ch....... 5-10

Table 5-15 RS-485 termination select jumper: W1 ............................. 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]......................................... 8-3

Table 10-1 Interrupt status port (ISP) map setting at I/O

location 0A9h ....................................................................... 10-4

Table 11-1 EZ I/O connectors: J15, J16 .............................................. 11-2

Table 11-2 EZ I/O port options .............................................................. 11-2

Table 11-3 EZ I/O pull-up/pull-down jumpers: W4 ............................. 11-3

Table 11-4 EZ I/O port address ............................................................. 11-4

Table 11-5 Reading EZ I/O 1 and EZ I/O 2 port addresses at I/O

location 0A9h ....................................................................... 11-4

Table 11-6 EZ I/O port byte................................................................... 11-5

Table 11-7 EZ I/O opto-rack interface ................................................ 11-13

Table 12-1 Phoenix BIOS beep codes.................................................... 12-2

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 .......... 13-7

Table 14-1 GPS interface default and optional features ..................... 14-3

Table 14-2 Jupiter GPS mode ............................................................... 14-3

PC-510 user’s manual Contents

Table 20-1 User option jumper 1: W4 .................................................. 20-1

Table 20-2 User option jumper 2: W3 .................................................. 20-1

Table 21-1 Enhanced mode, CPU clock speed: W2[3-4] .................... 21-16

Table A-1 PC-510 memory map............................................................. A-2

Table A-2 PC-510 I/O map..................................................................... A-3

Table A-3 I/O map (Latched registered outputs via OctaGlue:

Address at X0A8h) ................................................................ A-4

Table A-4 I/O map (Configuration inputs via OctaGlue:

Address at X0A9h) ................................................................ A-4

Table A-5 COM1 available addresses ...................................................A-4

Table A-6 COM2 available addresses ...................................................A-5

Table A-7 Available LPT1 port addresses.............................................A-5

Table A-8 RS-485 termination select jumper: W1 ............................... A-5

Table A-9 BIOS and boot option jumper: W2 ....................................... A-6

Table A-10 Auxiliary option jumper: W3................................................A-6

Table A-11 EZ I/O pull-up/pull-down, user option jumper: W4 ............A-6

Table A-12 SRAM battery backup jumper: W5 .....................................A-7

Table A-13 Jupiter module antenna voltage select: W6........................ A-7

Table A-14 Flat panel interface voltage select: W8 ...............................A-7

Table A-15 Inverted shift clock signal voltage level select: W9 ............ A-7

Table A-16 Power connector: P8, P9....................................................... A-8

Table A-17 Speaker connector: J1 .......................................................... A-8

Table A-18 Keyboard connector: J2........................................................A-8

Table A-19 Mouse connector: J3 .............................................................A-9

Table A-20 AT and industrial serial for COM3 and COM4: J4 ............ A-9

Table A-21 AT and industrial serial for COM5 and COM6: J5 .......... A-10

Table A-22 LPT1 as printer connector: J6 ...........................................A-11

Table A-23 AT and industrial serial for COM1 and COM2: J7 .......... A-11

Table A-24 Floppy drive connector: J9 ................................................. A-12

Table A-25 IDE hard drive connector: J10........................................... A-13

Table A-26 PC/104 signal assignments: J11........................................ A-14

Table A-27 GPS (Jupiter) connector: J13.............................................A-15

Table A-28 Flat panel connector: J14...................................................A-16

Table A-29 EZ I/O 1 connector (J15) and EZ I/O 2 connector (J16) ....A-17

Table A-30 OPTOA and OPTOB: J17 ..................................................A-17

Table A-31 Battery connector: J18 ....................................................... A-17

Table A-32 PC video connector: J19 .....................................................A-18

Table A-33 SVGA connector: J20.......................................................... A-19

Table D-1 PC-510 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-4

Contents PC-510 user’s manual

xii

PC-510 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. 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, EPROM, or flash

device 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-510 single board

computer. Refers to all versions of PC SmartLINK. PC Video A feature on the PC-510 which imports an external

video source into the virtual graphics array (VGA)

system. This feature allows for advanced video

connections including video overlays.

xiii

Abbreviations and terms used in this manual PC-510 user’s manual

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, EEPROMs, and flash

memory. 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-510 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]

Follow these rules and conventions: n Information which appears on your screen is shown in a different

type face, for example:

n Commands that you must key in are shown in Courier Bold, for

example:

input {optional_input

}

C:> RESET

Conventions used in this manual PC-510 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-510 user’s manual About this manual

About this manual

The PC-510 user’s manual provides information about installing and configuring the PC-510. 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: GPS interface Chapter 15: PC/104 expansion

n Section 3 – System management

Chapter 16: Watchdog timer and hardware reset Chapter 17: Serial EEPROM and CMOS RAM Chapter 18: Transferring files/remote disks Chapter 19: Managing SSDs Chapter 20: User-defined jumper Chapter 21: CPU power management Chapter 22: 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-510 user’s manual

PC-510 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-510 user’s manual

PC-510 user’s manual Overview

Chapter 1:

≡ Description

The PC-510 Mobile Industrial Computer™ (MIC) is a high performance, single board PC in Octagon’s semi-custom product line. The PC-510 integrates serial communication, industrial digital I/O, a floppy and a hard disk port, a multifunctional parallel port, and a local bus video which supports monitors and flat panels. It has an interrupt routing matrix, two solid-state disks, and a PC/104 interface. The PC-510 can have up to 16 MB of on-board DRAM. 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.

Specified to your engineering needs, the PC-510 can be ordered as a semi-custom board in OEM quantities. The stocked version of the PC-510 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-510 is usually application specific.

Overview

. Since the PC-510 uses the

≡ PC-510 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-510 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-510 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-510 to secure the DIMM module in high vibration environments. All surface mount DRAM and DIMM modules from Octagon meet the full PC-510 temperature range. Customers who need a 0° to 70°C range can install commercially available DIMM modules onto the PC-510.

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Overview PC-510 user’s manual

n 1 MB EDO surface mount standard n 4 MB EDO surface mount optional 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. To use an optional 512 KB SRAM, the PC-510 requires a factory change. The socket exhibits high retention force and affords a gas tight contact. SSD0 optionally contains the BIOS drive and ROMDOS 6.22 in ROM. By default, the optional SSD0 reserves 192 KB for BIOS and 320 KB for a 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 n SSD0 support from SRAM 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-510 utility disk. You can format the flash or SRAM while in the socket. EPROM usage, however, requires off-card programming from either a master flash or a master SRAM.

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-510 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-510 user’s manual Overview

Serial ports protected against ESD

The PC-510 can have either two or six serial ports. All six serial ports are standard, while COM5 and COM6 can be optionally omitted from the PC-510. 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 4-wire industrial RS-232, configurable to TTL for interface to a GPS receiver. COM6 is 4-wire industrial RS-232, configurable to a 2-wire RS-485. COM5 and COM6 are always supplied side by side. COM1 through COM6 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 COM6 standard n Omission of COM3 through COM6 optional

Local bus SV GA, flat panel interface, and GUI accelerator

The video system on the PC-510 uses the advanced 65550 video chip from Chips & Technologies. It supports CRT, LCD and EL displays with resolutions to 1280 x 1024 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-510 also supports 5V and newer generation displays, which use

3.3V.

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.

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Overview PC-510 user’s manual

n + Bias voltage 23V to 29V standard n – Bias voltage/other range optional n No bias supply optional

Industrial I/O using EZ I/O

The PC-510 can be supplied with 24 or 48 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.

n 48 lines standard n 24 lines optional n 0 lines optional

Speaker , keyboar d, 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 follows 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-510 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-510.

≡ PC-510 major software features

Advanced po wer management and system management input

1-4

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-510 to save its current status. When the system is

PC-510 user’s manual Overview

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-510 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 and “beep” codes chapter for a complete listing of tests and failures and their descriptions.

SETUP information stored in EEPROM f or 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-510 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-510.

Phoenix BIOS

The PC-510 has a Phoenix AT BIOS with power management and Octagon BIOS extensions. The AT BIOS supports up to four EIDE drives.

“Instant DOS” operating system

Datalight ROM-DOS v6.22 operating system is in flash. This means that this version is always present on powerup. The system boots and operates the same way as a desktop PC. Since all software and hardware are included, the system is fully operational “out of the box.”

Programmable video BIOS

The flash device contains a video BIOS, which controls the on-board SVGA controller. To support other flat panels, you can reprogram a new video BIOS. By default, the video BIOS supports a CRT and Sharp monochrome dual drive flat panel in simultaneous mode.

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Octagon PC-510 User Manual

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User Manual