Xycom 3500, 3515, 3515KPM, 3512KPM, 3515T Series Manual

Download

3500 Series Flat Panel

Industrial PC

with 6-slot ISA/PCI Expansion

P/N 350006(D)

 2002 XYCOM AUTOMATION, INC. Printed in the United States of America

3500 Series Flat Panel Industrial PC

Revision Description Date

A Manual Released 4/99 B Added 3515KPM 1/00 C Updated Bulb Replacement Instructions 11/00 D Touchscreen Updates 7/02

Trademark Information

Brand or product names are registered t r ademarks of their respective own er s. Windows is a registered trademark of Microsoft Corp. in the United States and other countries.

This document is copyrighted by Xycom Automation Incorporated (Xycom Automation) and shall not be reproduced or copied without expressed written authorization from Xycom Automation.

The information contained within this document is subject to change without notice. Xycom Automation does not guarantee the accuracy of the information and makes no commitment toward keeping it up to date.

United States FCC Part 15, Subpart B, Class A EMI Compliance Statement:

NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are des igned to pr ovide reason able protec tion aga inst h armful in terference when the equ ipment i s operated in a commerci al environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interferen ce in which case the user will be required to correct the interference at his own expense.

For European Users:

WARNING This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take

adequate measures.

INSTALLATION: Electromagnetic Compatibility WARNING

The connection of non-shielded equipment interface cables to this equipment will invalidate FCC EMI and European Union EMC compliance and may result in electromagnetic interference and/or susceptibility levels which are in violation of regulations which apply to the legal operation of this device. It is the responsibility of the system integrator and/or user to apply the following directions which relate to installation and configuration:

1. All interface cables must include shielded cables. Braid/foil type shields are recommended. Communication cable connectors must be

metal, ideally zinc die-cast backshell types, and provide 360 degree protection about the interface wires. The cable shield braid must be terminated directly to the metal connector shell, ground drain wires alone are not adequate.

2. For systems other than Pentium II logic board (AHIP6+): In those cases where an external mouse is used, the snap-on ferrite bead provided

(P/N 116046) must be installed on the mouse cable at the host end in order to comply with relevant EMI regulations.

3. Protective measures for power and interface cables as described within this manual must be applied. Do not leave cables connected to

unused interfaces or disconnected at one end. Changes or modifications to this device not expressly approved by the manufacturer could void the u ser’s authority to operate the equipment.

4. EMC compliance is, in part, a function of PCB design. Third party add-on AT/XT peripheral PCB assemblies installed within this appara-

tus may void EMC compliance. FCC/CE compliant PCB assemblies should always be used where possible. XYCOM AUTOMATION can accept no responsibility for the EMC performance of this apparatus after system integrator/user installation of PCB assemblies not manufactured and/or expressly tested and approved for compliance by XYCOM AUTOMATION. It is the responsibility of the system integrator/user to ensure that installation and operation of such devices does not void EMC compliance.

Xycom Automation

Technical Publications Department 750 North Maple Road Saline, MI 48176–1292 734-429-4971 (phone) 734-429-1010 (fax)

Table of Contents

Chapter One – Introduction........................................................................................................................5

Product Overview......................................................................................................................................................5

With AHIP6+ board ...............................................................................................................................................5

With AHIP370+ board...........................................................................................................................................5

On all units .............................................................................................................................................................5

Unpacking the System...............................................................................................................................................7

Quick Start-up...........................................................................................................................................................7

Chapter Two – Testing................................................................................................................................ 9

Preparing for the Tests ..............................................................................................................................................9

Running the Tests....................................................................................................................................................11

Chapter Three - Installation...................................................................................................................... 12

System Components................................................................................................................................................ 12

Installation Options................................................................................................................................................. 20

SDRAM and Additional SDRAM Dual In-Line Memory Modules (DIMMs)..................................................... 20

PC/AT or PCI Boards...........................................................................................................................................20

Externally Mounted Floppy Drive........................................................................................................................21

Front Access Keyboard and Floppy Connectors...................................................................................................23

Serial AUX...........................................................................................................................................................25

Creating a Custom Logo..........................................................................................................................................25

3515......................................................................................................................................................................25

3512KPM/3515KPM ........................................................................................................................................... 25

Creating Custom Keypad Inserts (3512KPM/3515KPM only)...............................................................................26

Installing Operating Systems...................................................................................................................................28

Installing Drivers.....................................................................................................................................................29

Using a Touchscreen...............................................................................................................................................31

Video Expansion.....................................................................................................................................................35

Mounting Considerations........................................................................................................................................36

AC Power Cable...................................................................................................................................................39

Cable Retainer Bracket.........................................................................................................................................41

Mounting the Unit.............................................................................................................. .....................................41

Hazardous Locations Installations...........................................................................................................................43

Class I Locations..................................................................................................................................................44

Class II Locations.................................................................................................................................................44

Division 1 Locations.............................................................................................................................................45

Division 2 Locations.............................................................................................................................................45

Groups..................................................................................................................................................................45

Safety Agency Approval..........................................................................................................................................47

Chapter Four – Keypad Utility Program..................................................................................................48

Loading the Keypad Utility.....................................................................................................................................48

Using the Keypad Utility.........................................................................................................................................48

Main Menu..............................................................................................................................................................49

Keypad Scan Codes.................................................................................................................................................53

Chapter Five - Maintenance .....................................................................................................................57

Xycom Recommended Hard Drive Preventative Maintenance ...............................................................................57

Appendix A – Technical Specifications ..................................................................................................63

3500 Series Flat Panel Industrial PC

Hardware Specifications..........................................................................................................................................63

Environmental Specifications..................................................................................................................................63

Appendix B – Block Diagrams.................................................................................................................65

Appendix C – Pinouts............................................................................................................................... 67

Keyboard Port Connectors......................................................................................................................................67

Aux Port Connector.................................................................................................................................................67

Dual USB Connector (USB1) .................................................................................................................................67

Parallel Port Connector (LPT1)...............................................................................................................................68

Serial Port Connectors.............................................................................................................................................68

VGA Connector.......................................................................................................................................................69

External Floppy Connector......................................................................................................................................70

Appendix D – Replacing Flat-Panel Display Bulbs................................................................................71

Chapter One – Introduction

Product Overview

The 3500 series of flat panel industrial PCs with 6-slot ISA/PCI expansion include the 3515, 3515T, 3515KPM, and 3512KPM models. These industrial PCs offer a powerful, compact package for the factory floor and other harsh environments. The 3515 is an industrial PC with a display only (touchscreen optional). The 3512KPM and 3515KPM is an industrial PC with a display, integrated keypads, and an integrated mouse.

They feature an open architecture to meet a wide variety of applications that require both a powerful PC and a durable industrial front panel. The PCs integrate a computer card cage, mass storage, display, and power supply in a truly industrial form. Their modular design allows easy access to expansion boards, jumpers, power supply, flat panel display, and disk drives.

The front panel of every model is sealed to NEMA 4/4X/12, and the flat panel display is protected by an impact-resistant shield.

Chapter Two - Testing

Standard Features

With AHIP6+ board

• Pentium® III technology

• PCI 64 bit video controller, 2 MB video RAM

• PCI local-bus IDE controller

• Two 168-pin SDRAM DIMMs that support 32, 64, 128, and 256 MB options

• Two USB ports

• 100MHz front side bus with Pentium III processors

With AHIP370+ board

• Celeron ® technology

• AGP 64 bit video controller, 2 MB video RAM

• PCI local-bus IDE controller

• Two 168-pin SDRAM DIMMs that support 32, 64, 128, and 256 MB options

• Two USB ports

On all units

Two serial COM ports

• COM 1

• RS-232 or RS-485 (DB9 connector)

• RS-232 (DB25 connector)

3500 Series Flat Panel Industrial PC

• Flat panel display

• 15-inch flat panel, 1024x768 resolution (3515T and 3515KPM)

• 12.1-inch flat panel, 800x600 resolution (3512KPM)

• Parallel port

• VGA port

• Flash BIOS

• 9-inch mounting depth

• 3.5-inch internal, side access floppy drive

• Six AT-bus full-length expansion slots

• Five ISA slots

• One PCI or four ISA slots

• Two PCI slots (4.8” maximum length with AHIP6+ board)

• IR Port (IrDA and ASKIR compatible)

• Rear PS/2 keyboard port and AUX port (also a front PS/2 keyboard port on

3512KPM and 3515KPM)

• Status LEDs

• Power

• Disk

• Com

• Input

• 3.5-inch internal IDE hard drive

• MS-DOS

• Front panel sealed to meet NEMA 4/4X/12 specifications when panel mounted in a

suitable fire and electrical enclosure.

• Approved for use in Class I, Division 2 hazardous locations

• Autosensing AC power supply

• Side power connector with retainer bracket

Optional Features

• Touchscreen resistive technology with less than 1.5% linearity error

• Higher capacity IDE hard drives and solid state drives

• 3512KPM

• 40 relegendable function keys (80 with the F/A function)

• Numeric, PC control, and alpha keypads

• Integrated mouse

• 3515KPM

• 40 relegendable function keys (80 with the F/A function)

• Numeric, PC control, and alpha keypads

• Windows start menu and pop-up menu keys

• Integrated mouse

• Flat-panel display

• 15.0-inch TFT flat panel (3515 and 3515KPM)

• 12.1-inch TFT flat panel (3512KPM)

• CD-ROM (internal)

• Pre-installed PCI 10/100 Base-T Ethernet card

• External floppy drive 9000-EXF

• Front mount floppy kit 9000-FFK

• Front access panel for floppy port and keyboard port 9000-FKA

• Preloaded Microsoft

Unpacking the System

When you remove the system from its box, verify that you have the parts listed below. Save the box and inner wrapping in the event you need to reship the unit.

• 3515, 3515KPM, or 3512KPM unit

• AC power connector

Chapter Two - Testing

Windows 95 or Windows NT® operating system

• Power connector retainer bracket with AC power supply

• Sixteen 10-32 hex nuts (2 spares)

• Clip-on Ferrite for AUX cables

• Documentation kit, which includes:

• Diagnostic software disk (only on units shipped with DOS)

• VGA utility disk

• 3515/3512KPM manual

• CPU manual

• Business reply card

If you ordered the system with a touchscreen installed, you will also receive a touchscreen driver disk and manual. If you ordered a CD-ROM installed, you will receive the driver disk. If you ordered a 3512KPM or 3515KPM, you will receive a mouse disk and manual. If you ordered the system with an Ethernet card you will receive a driver disk.

Quick Start-up

This section provides the steps to get your unit up and running without explaining the capabilities and options of the system.

Turn off power to the unit and disconnect the power cord before making any adjustments to the inside or the outside of the computer.

Perform the following steps to prepare the system for use.

Warning

3500 Series Flat Panel Industrial PC

1. Attach an optional keyboard to the keyboard port.

2. Attach other optional equipment following the instructions in Chapter 3.

3. Attach the power cord from the power receptacle to a properly grounded 115/230

VAC, 50-60 Hz outlet or a 24 VDC outlet, whichever applies (Refer to the Creating a Power Cable section in Chapter 3 for more information.)

4. Turn on the power to the unit. Depending on your operating system, one of the fol-

lowing will occur:

• In DOS, the system will boot up at the C: prompt

• In Windows 95 or Windows NT the License Agreement will be displayed

5. Install application software via the floppy, a network connection, the IR port, or a

CD-ROM.

Chapter Two – Testing

On units with MS-DOS installed, diagnostic tests are provided as a tool to verify the operation of system hardware functions. If any of these tests fails, either you do not have the correct default setting or there is a failure. Check the default settings and run the tests again. If another failure occurs, contact Xycom Automation’s Product Repair & Customization Department (see Chapter 5).

Remove any device drivers or memory resident programs (TSRs) installed on the system before running Xycom Automation diagnostic tests. If you do not, unexpected failures may occur.

The diagnostic disk does not provide an option to test a CD-ROM drive.

Chapter Two - Testing

Note

Make sure the BIOS setup menus are configured properly (factory set configuration). To enter the BIOS setup menus,

1. Press

2. Make the necessary changes by following directions on the screen.

3. Press

4. Press ENTER twice to save the settings and exit the BIOS setup menus. Refer to your CPU manual for more information on the BIOS setup menus.

F2 after the POST RAM test has completed.

ESC.

Preparing for the Tests

You need the following equipment to test your system:

• Floppy disk drive

• Xycom Automation System Test Disk (3.5-inch, DS/DD bootable disk, Xycom

Automation part number 99290-001)

• Centronics-compatible printer cable

• Parallel printer (Centronics-style interface)

• Two serial loopback test connectors (refer to Figure 2-12-1 for pinouts)

• Formatted 3.5-inch, DS/HD disk (1.44 MB)

• IBM PC/AT or PS/2 compatible keyboard

3500 Series Flat Panel Industrial PC

Perform the steps below before starting the system tests:

1. Place the CPU board jumpers and switches to the factory set positions. Refer to your

CPU manual for these settings.

2. Plug the female end of the AC power cable into the side of the unit and the male end

into a properly grounded outlet.

3. Connect the serial loopback connector(s) and the printer cable to the appropriate

connectors and connect a PC/AT or PS/2 keyboard. Figure 2-1 illustrates the wiring necessary for the loopback connection.

4. Default the CMOS setup to the factory settings.

Figure 2-1. Serial Loopback Connections

Running the Tests

To run the test, insert the diagnostics disk into drive A. Turn on the computer (the diagnostics program will boot-up). Figure 2-2 shows the Main Menu.

Chapter Two - Testing

Diagnostic Tests Sequence/Selection Menu (Rel. xx)

1. WILL pause on error

2. SINGLE PASS test mode

3. Save setup to file

4. Extract setup from a file

A) RAM Test B) Video RAM Test C) Extended RAM Test D) Real Time Clock Test E) COM1 Serial Port Test F) COM2 Serial Port Test G) COM3 Serial Port Test H) COM4 Serial Port Test I) Math Coprocessor Test J) Video Adjustments Test

[ENTER]=START TESTING

Use the letters to move the cursor and select/deselect, or use the arrow keys to move, then use the [SPACE] key to select/deselect a test or function.

Figure 2-2. Main Menu

5. Auto-select tests

6. Deselect all tests

7. Quit and exit to DOS

8. Return to previous screen

K) Video Interface Test L) Speaker Port Test M) LPT1: Printer Port Test N) LPT2: Printer Port Test O) C: Hard Drive Interface Test P) D: Hard Drive Interface Test Q) A: Floppy Drive Interface Test R) B: Floppy Drive Interface Test S) Keyboard, Keypad Tests ≡ = Test Selected

Please read the DIAG.TXT file on the diagnostics disk for detailed information about the tests.

Avoid repeated running of any hard disk diagnostic utility if you use the Solid State (Flash) drive option. The Flash drive has a limited number of writes to each logical sector. Repeated writes from a diagnostic utility will prematurely shorten the life of the drive.

Note

3500 Series Flat Panel Industrial PC

Chapter Three - Installation

System Components

This section describes the components on the unit to help you locate features relevant to installation.

3515 Front Panel

The 3515 comes with a NEMA 4/4X/12 and IP65 sealed front panel with a TFT (Figure 3-3) display. The panel protects the system’s interior when the system is properly panel mounted.

TOUCH

SCREEN

(OPT IONAL)

POWER DISK COM INPUT

IR P O R T

IR PORT POWER DISK

COM

INPU T

Figure 3-1. 3515 TFT Active Display Front Panel

Chapter Three - Installation

Feature Description

Display The 3515 comes standard with a 15-inch TFT flat panel. Impact-resistant shields

protect the displays from breakage. If a touchscreen is factory installed, the touchscreen is backed by heat-annealed safety glass replacing the impactresistant shield.

System Status LEDs The 3515 features four status LEDs on the front panel, which you can use to

monitor system operation. Power There is power to the 3515. Disk The computer module is accessing the disk drive. COM There is communication activity on one of the computer module’s serial

ports, including communication between the computer module and the touchscreen (if on COM2) or a serial device.

Input The unit has a touchscreen and the LED gets brighter when touch input

is detected.

During power-up, firmware on the processor board checks the hardware configuration against the configuration stored in the CMOS memory.

IR (Infrared) The IR port transceiver is loc ated behind this window. The 3515 IR por t is Ir DA,

and ASK-IR compliant. You can connect the 3515 to any IrDA compatible device, if you load special software (not included). T he inf r ared ( IR) link oper ates at a distance of 0 to 1 meter and is capable of 115 Kbaud transfer rates. Enable the interface through the BIOS setup m enus.

COM2 is not available. Correspondingly, if COM2 is in use by the touchscreen the IR is not operational.

Note: When the IR port is chosen,

3500 Series Flat Panel Industrial PC

3512KPM and 3515KPM Front Panel

The 3512KPM (Figure 3-2) and 3515KPM (figure 3-3) comes with a NEMA 4/4X/12 sealed front panel. The panel protects the system’s interior when the system is properly panel mounted.

FLAT-PANEL

DISPLAY

PROGRAMMABL E

FUNCTION KEYS

(PF1-PF10)

CONFIGURATION

KEY (PF10)

xycom

PF1

PF2

PF3

PF4

PF5

PF6

PF7

PF8

PF9

PF10

F1 F2 F5 F6 F7 F8 F9 F10

F3 F4

KL OPQRST

F11F12F13F14F15F16F17F18F19F20

UVWXYZ

PROGRAMMABLE FUNCTION KEYS (PF11-PF20)

CTR L

SHIFT

ALT

TAB

SPACE

123

456

789

PgUp

HOME

PgDn

ENTER

ESC

DEL

BACKSPACE

PF11

(

PF12

)

PF13

PF14

PF15

PF16

PF17

PF18

PF19

PF20

POWER DISK COM INPUT

F/A KEY

NUMERIC KEYPAD

CURSOR CONTROL

SYSTEM STATUS LEDS

KEYBOARD &

IR-PORT ACCESS DOOR

Figure 3-2 3512KPM Front Panel with Keypad

Figure 3-3. 3515KPM Front Panel with Keypad

FUNCTION KEYS (F1-F20) MOUSE

Chapter Three - Installation

Feature Description

Display The 3512KPM comes standard with a 12.1-inch TFT flat panel. The 3515KPM

comes standard with a 15-inch TFT flat panel. Impact-resistant shields protect the display from breakage. If a touchscreen is factory installed, the touchscreen is backed by heat-annealed safety glass replacing the impact-resistant shield.

System Status LEDs You can use LEDs on the front panel to monitor system operation.

Power Lit when there is power Disk Lit when the computer is accessing the disk drive. COM Lit when there is communication activity on one of the serial ports, in-

cluding communication between the computer module and the touchscreen (if on COM2) or a serial device.

Input Lit when the unit has a touchscreen; the LED gets brighter when a touch

input is detected or a key is pressed. F/A key Lit when alpha characters are being returned. During power-up, firmware on the processor board checks the hardware configu-

ration against the configuration stored in the CMOS memory.

Function and UserDefined Keys

The 40 relegendable function keys (80 using the F/A key) provide easy access to familiar routines. (The F/A key can be used for alpha and symbol entry). See the Customizing Keypad Inserts section in this chapter for details on customizing your keypad inserts.

Numeric/Cursor

The data entry keypads are for entering data and moving the cursor.

Control Keypad Windows keys

(3515KPM only)

These keys access the star t menu and pop-up menus in the Windows NT or 95 operating system.

F/A Key When the LED is lit, alpha characters are r eturned. PF10 Key (Keypad

This key configures your keypad.

Configuration) Keyboard Port (front

access)

The 3512KPM and 3515KPM support one PS/2 keyboard, located on the lower left side of the front panel. On the 3512KPM the port is behind an ac c ess door . When using this por t, the side por t cannot be us ed.

Mouse The built-in pointing device is located on the right-hand side of the front panel. It

operates in the same manner as a conventional mouse. Refer to the mouse diskette and manual supplied with your documentation kit. This mouse consists of three basic parts:

Left mouse key Serves the same function as the left button on a conventional

mouse.

Mouse dome Moves the pointer around the screen. Press the edge of the

dome that corresponds to the direction in which you wish to move the pointer.

Right mouse key Serves the same function as the right button on a conven-

tional mouse.

3500 Series Flat Panel Industrial PC

I/O Panel

Figure 3-4 illustrates the I/O Panel on the right side of the 3515 and 3512KPM.

LID LATCH (2)

(on back)

EXPANSION

SLOTS (6)

LID

ETHERNET

PORT

(OPTIONAL)

SAFETY

RETENTION

SCREW (2)

MOUNTING

STUD (14)

FRONT

PANEL

COM 2 RS-232

PARALLEL RS-232

COM 1 RS-485

AUX

KEYBD

USB1

VIDEO

3.5" FLOPPY DRIVE

5.25" DRIVE BAY KNOCK OUT OR CD-ROM

VENT FILTER (on bottom)

Figure 3-4. 3515/3512KPM I/O Panel

Feature Description

Parallel Port The parallel printer port (LPT1) is a stacked DB-25 pin female connector.

This port provides a standard PC compatible printer interface. An external push-button reset option is available. Consult the CPU board manual for the jumper which controls this option.

COM Ports COM1 consists of two connectors (RS-232 and RS-485) attached to one

logical port. Only one connector can be used at a time. COM2 consists of one connector (RS-232).

Keyboard Port The keyboard port is a PS/2 stacked mini-din that allows you to attach a

PC/AT keyboard at the side of the unit. Do not use in a hazardous environment. Note: You cannot use both keyboard ports on units that have

more than one keyboard port.

USB Port USB (Universal Serial Bus) is a "plug-and-play" interface between a com-

puter and add-on devices (such as audio players, joysticks, keyboards, telephones, scanners, and printers). With USB, a new device can be added to your computer without having to add an adapter card or even having to turn the computer off. USB supports a data speed of 12 megabits per second. This speed will accommodate a wide range of devices, including MPEG-2 video devices, data gloves, and digitizers.

Chapter Three - Installation

Feature Description

AUX Port The AUX port is a PS/2 stacked mini-din that allows you to attach a serial

device (such as a mouse) at the side of the unit. The AUX port is the upper connector. If you receive a unit with a touchscreen, this port is covered with a label stating that the port is not functional as shipped.

Note: The AUX port is not available on the 3512KPM or 3515KPM. Also, when MS-DOS is installed, the touchscreen on the 3515T is fac tor y c onfigured for the AUX port. Plugging in a serial device while the touchscreen is attached will cause an err or mes s age during boot up and neither device will work. The touchsc reen mus t be rec onfigur ed for us e on COM2 for the AUX port to be functional.

Video Port The video port is a 15-pin D-sub VGA connector at the side of the unit.

This connector supports any standard VGA connection. The video port is disabled when shipped. This port is active if an LCD flat panel is not connected. A jumper can be used to switch between the VGA port and the LCD. To use both a video display on the video port and the flat panel display, you must enable “Simultaneous Video” (only available on the TFT version) on the Advanced Menu in the BIOS setup menus. Refer to the CPU manual for details.

CD Drive (Optional) There is a 5¼-inch drive-bay knockout for a CD drive.

Caution: If you have a CD-ROM installed, use of controls, adjustments, or the performance of procedures other than those specified herein may result in hazardous ra diation exposure.

Floppy Drive The 3.5-inch internal floppy drive is on the I/O side. The systems have a

front mounted external floppy drive option and a front mounted floppy/keyboard access option. Do not order the unit with an internal floppy drive if you want to use these options.

Expansion Slots There are six slots available: five ISA slots, one PCI bus expansion slot or

four ISA, and two PCI bus expansion slots. Note: If the optional Ethernet

card is installed, only five slots are available.

Ethernet Port (optional) The Ethernet port provides a 10BASE-T/100BASE-TX auto sensing

Ethernet connection.

3500 Series Flat Panel Industrial PC

Back Panel

Figure 3-5 illustrates the system’s back panel.

SAFETY

RETENTION

SCREW (4)

LID

LID LATCH (2)

MOUNTING

STUD (14)

BACK PANEL

If your system has a touchscreen, keypad, keypad LED, or mouse cable, disconnect the cable(s) from the CPU board before removing the back of the unit from the front bezel.

To remove the lid, lift the two latches along the top of the back panel. To remove the front panel, use a Phillips-head screwdriver and remove the four screws

located in the top and bottom corners (refer to Figure 3-5).

Bottom Panel

The features on the bottom panel are listed below.

Feature Description

Product ID Label

Vent and Filter The bottom of the unit contains a vent and filter for circulation. This

Figure 3-5. Back Panel

Note

The product ID label is located on the back panel. This label contains the model number and serial number of the unit.

aids in the cooling of the internal components.

Power Panel

Chapter Three - Installation

EXHAUS T

FAN

VENT

FILTER

(on botto m)

MONITOR

AUXILIAR Y

OUTLET

POWER

RECEPTACLE

RETAINER

BRACKET

MOUNTING

STUD (2)

FRONT

PANEL

EXHAUST

FAN

VENT

FILTER

(on bottom)

100-120V~ 3A MA X .

200-240V~ 2A MA X .

50/60Hz

Figure 3-6. Unit with AC Power Supply

LID LATCH (2) (on back)

LID (on top)

FAN FILTER

RETENTION SCREW (2)

MOUNTING STUD (14)

LID LATC H (2) (on back)

LID (on top)

DC POWER

STRIP

+24VDC

0VDC

CHASSIS GROUND

RETAINER

BRACKET

MOUNTING

STUD (2)

FRONT

PANEL

FAN FILTER

+24 0V

RETENTION SCREW (2)

MOUNTING STUD (14)

Figure 3-7. Unit with DC Power Supply

3500 Series Flat Panel Industrial PC

Feature Description

Power Receptacle The AC power receptacle is a three-pin connector on the left side of

the unit; the DC power supply uses a terminal block.

Monitor Auxiliary Power Outlet The outlet is intended for use only in testing situations, outside haz-

ardous locations, and is covered by a retainer bracket for safety reasons. Note: A flat panel display and a CRT cannot be used simulta-

neously on a display. Simultaneous video is only available on TFT systems with the “Simultaneous Video” utility program, or configured in the BIOS setup menus..

Retainer Bracket (AC) or PClamp (DC)

Fan and Filter The fan and filter, located on the left side panel, are cooling system

Exhaust Fan The exhaust fan is a cooling system component. Vent Filter The vent and filter is a cooling system component to allow air to circulate.

With an AC power supply, this bracket can be screwed into the two studs, as shown in 3-21, to retain the power connector and to cover the Monitor Auxiliary outlet. If an optional DC power supply is installed, use the P-Clamp to provide power cord strain relief.

Warning: Absence of this bracket may result in a disengaged power connector. If this occurs, an explosion may result in a hazardous environment.

components. The filter is replaceable and can be removed for cleaning.

Installation Options

This section describes how to install internal and external hardware options.

Internal Hardware Options

Turn off the unit and remove power before installing internal hardware.

To install internal hardware options unlatch and remove the lid.

SDRAM and Additional SDRAM Dual In-Line Memory Modules (DIMMs)

You can order your unit CPU factory-configured for many configurations of SDRAM. You can reconfigure the SDRAM capacity by changing the SDRAM DIMMs on your board. For more information, refer to the CPU manual.

PC/AT or PCI Boards

1. Check that the memory and I/O configuration of the board you want to install do not

conflict with the CPU and I/O memory maps in your CPU board manual.

Caution

2. Using the two latches, remove the lid.

3. Remove the ORB screw and blank ORB from the desired track.

Chapter Three - Installation

4. Slide the PC/AT or PCI expansion board into a corresponding rail.

5. Push the board into the backplane connectors.

Note

Do not force the boards or apply uneven pressure.

6. Secure the board by installing the screw through the hole in the board’s metal ORB

and into the top of the track.

7. Replace and relatch the lid.

Caution

On Pentium II equipped units, do not block the CPU fan when installing a card in the slot closest to the processor. The processor may overheat.

External Hardware Options

The 3515 and 3512KPM supports front access to keyboard and floppy drive connectors with the 9000-FKA kit and front access to an externally mounted floppy drive with the 9000-FFK kit.

To maintain a safe condition, do not use an external keyboard or mouse or USB port devices when the unit is operating in a hazardous environment.

Externally Mounted Floppy Drive

The connector for the external floppy is mounted in the location of the internal floppy bay. Since the 3515/3512KPM supports one floppy drive, you cannot use the external floppy option if the unit has an internal floppy drive.

The floppy drive access door is provided for installations using the filler with cutout, or panel mount installations that provide a cutout for the front mounted floppy drive. See Figure 3-8 for cutout dimensions.

Make sure the floppy drive cable reaches the floppy connector on the unit before making the cutout.

Warning

Note

3500 Series Flat Panel Industrial PC

Figure 3-8. Front Mounted Floppy Cutout Dimensions

Mount the floppy drive access door to the filler plate or the panel, using the four mounting nuts as shown in Figure 3-9. Torque the nuts to 35 in/lb. (3.95 Newton Meters).

Figure 3-9. Floppy Drive - Front Mounting Option

Figure 3-10 shows an overhead view of the Front Floppy Kit with the floppy drive mounted into the rack.

Note

Do not attach the drive with a disk installed to avoid corrupting a disk when using the external floppy drive.

Chapter Three - Installation

Figure 3-10. Floppy Drive - Front Mounting Option (top view)

Front Access Keyboard and Floppy Connectors

You can access these keyboard and floppy drive connectors with the 9000-FKA kit in installations that provide a cutout for the front mounted connections, you must install the 9000-FKA kit. The kit’s keyboard cable connects to a PS/2 stacked mini-din located on the side of the unit. The floppy drive cable connects to a port mounted in the internal floppy bay. Since the 3500 series only supports one floppy drive, you cannot use the external floppy option if the unit has an internal floppy drive. See Figure 3-11 for cutout dimensions.

Note

Make sure the keyboard and floppy drive cables reach the ports on the unit before making the cutout.

3500 Series Flat Panel Industrial PC

Figure 3-11. Front Mounted Connectors Cutout Dimensions

Mount the front floppy and keyboard access kit to the plate or the panel as shown (3-12). Torque the nuts to 35 in/lb. (3.95 Newton Meters).

Figure 3-12. Front Floppy and Keyboard Access Option

The 3500 series supports one floppy drive. If you want to use the floppy drive connector, the unit cannot have an internal floppy drive. (The external floppy’s connector is mounted in the internal floppy bay.)

Note

Serial AUX

If an auxiliary device is used, the ferrite included in the documentation kit must be installed to maintain CE compliance.

The AUX port is disabled when a touchscreen is factory installed.

Creating a Custom Logo

This section provides the necessary information to create a custom logo.

3515

After you create a label, remove the Xycom Automation label and place your custom logo label in the pocket. Refer to Figure 3-13 for the dimensions and recommended requirements.

Chapter Three - Installation

Note

Figure 3-13. 3515 Logo Label Dimensions

3512KPM/3515KPM

After you create a label, remove the Xycom Automation label and place your custom logo label in the pocket. Refer to Figure 3-14 for label dimensions.

Figure 3-14. 3512KPM/3515KPM Logo Label Dimensions

3500 Series Flat Panel Industrial PC

Creating Custom Keypad Inserts (3512KPM/3515KPM only)

You can customize your keypad with keypad inserts. Refer to Figure 3-15 and Figure 316 for insert dimensions and installation.

Figure 3-15. Keypad Inserts with Dimensions (PF1 - PF20)

Chapter Three - Installation

Figure 3-16. Keypad Insert with Dimensions (F1 - F20)

Figure 3-15 provides information on positioning keypad inserts.

3500 Series Flat Panel Industrial PC

Figure 3-17. Keypad Insert Position

Installing Operating Systems

The system CPU comes with MS-DOS standard. The pre-installed operating systems are provided in the following format:

Operating Systems Format

DOS Diskette Windows 95 CD ROM Windows NT CD ROM

If you want to install a new operating system or re-install a current operating system, refer to the operating system’s manual for directions.

If you need to reinstall Windows NT system, you must have an internal CD-ROM drive or an external parallel port CD-ROM drive as Windows NT only ships on a CD-ROM disk.

Note

Installing Drivers

This section describes how to install the drivers associated with the 3500 series.

Ethernet Drivers

If Windows 95 or Windows NT 4.0 is pre-installed on your system and you ordered the Ethernet card option, Ethernet drivers are installed on your hard drive in the C:\netdrv directory.

If you want to use Ethernet capabilities with Windows 95, your system must have BIOS revision level 1.1 or higher.

If MS-DOS is installed on your system, the Ethernet drivers are supplied on your hard drive in the C:\netdrv directory, but they are not installed.

To install the MS-DOS Ethernet drivers,

Chapter Three - Installation

Note

1. At the C: prompt, type “cd netdrv”.

2. Once the C:\netdrv path is specified, type “install”.

3. Follow the on-screen instructions to complete installation. If you install Windows 3.1 on your system, Xycom Automation provides the Ethernet

drivers. They can be found on the Ethernet Drivers disk that ships with your system.

If you install Windows NT 4.0 or Windows 95 on your system , the Ethernet drivers that are provided do not work with the Ethernet controller installed. You must use the drivers provided by Xy com Automation. These drivers can be found on the Ethernet Drivers disk that ships with your system.

Consult the Info directory on the drivers disk for additional installation information.

Video Drivers

Video drivers for each operating system are on the diskettes included with the documentation kit. To install a video driver, refer to the INSTALL.TXT file on the diskette for your operating system.

Note

3500 Series Flat Panel Industrial PC

Touchscreen Drivers

Depending upon the date of purchase, the Xycom Automation unit will have one of two possible touchscreen controllers:

• The Microtouch Controller P/N 114084

• The Xycom Controller P/N 140554

These controllers function similarly. However, the following sections require attention to the type of controller installed.

Microtouch Controller

If the touchscreen is factory-installed, you will receive a disk with MSDOS and Windows 95 touchscreen drivers. If Windows 95 or Windows NT is factory-installed, the touchscreen drivers are provided. If you change the operating system, you must install the corresponding touchscreen driver software. Refer to the touchscreen manual for instructions.

Note

Xycom Controller

If the touchscreen is factory-installed, you will receive a CD with MSDOS and Windows touchscreen drivers. If Windows is factory-installed, the touchscreen drivers are provided. If you change the operating system, you must install the corresponding touchscreen driver software. Refer to the touchscreen manual for instructions.

CD-ROM Drivers

A CD-ROM driver disk comes with the CD-ROM option, as well as the preinstalled driver for the operating system you have selected. If you change operating systems and need help loading the required CD-ROM driver, contact Xycom Automation technical support at 1-800-289-9266 x450.

If the Windows or Windows NT operating system is factory installed, then touchscreen is set up on COM2, making this port unavailable.

If you need to reinstall Windows NT, you must have an internal CDROM drive or an external parallel port CD-ROM drive as Windows NT only ships on a CD-ROM disk.

Note

Use of controls, adjustments or the performance of procedures other than those specified herein may result in hazardous radiation exposure.

Miscellaneous Drivers

Refer to your operating system and peripheral manuals for information on installing drivers related to these items.

Using a Touchscreen

The Xycom Automation touchscreen, based on resistive membrane technology, consists of two layers with transparent, conductive coatings on the facing sides. Finger or stylus pressure causes the outer layer to make electrical contact with the inner layer. Xycom Automation’s touchscreen complies with environmental specifications and maintains a NEMA 4 seal when panel mounted. It remains operational even after 30 million touches.

Chapter Three - Installation

Caution

The touchscreen interface module circuit impresses a voltage across the conductive coatings. When the touchscreen is pressed the circuit converts from analog to x and y digital coordinate positions and then passes the x and y codes to the installed touchscreen driver. The touchscreen Monitor Mouse driver emulates a Microsoft pointer.

Note

Refer to the touchscreen manuals (included in the Documentation kit) for complete driver installation details.

Depending upon the date of purchase, the Xycom Automation unit will have one of two possible touchscreen controllers:

• The Microtouch Controller P/N 114084

• The Xycom Controller P/N 140554

These controllers function similarly. However, the following sections require attention to the type of controller installed.

Microtouch Controller

Note

If touchscreen is factory installed along with MS-DOS, the touchscreen is set up on the AUX port, making this port unavailable.

If the Windows 95 or Windows NT operating system is factory installed, then touchscreen is set up on COM2, making this port unavailable.

3500 Series Flat Panel Industrial PC

J1 J2

JUMPERS

J3 J4 J5

If you want to reconfigure the touchscreen to use the COM2 port, perform the following steps:

1. Disconnect the power.

2. Remove the lid.

3. Remove the touchscreen controller card (see Figure 3-18A).

TCTRL1

TOUCHSCREEN

NTROL CONN.

Figure 3-18A. Touchscreen controller card

4. Reconfigure jumpers J1-J9. Position A = COM2. Position B

= PS/2 AUX. (Note: all jumpers must be in the A or B position).

5. Reinstall the touchscreen controller card.

6. Reboot the computer.

7. Using the touchscreen manual, do the following:

• Load the touchscreen drivers

• Reconfigure the touchscreen driver for COM@

• Recalibrate the touchscreen

8. Replace the lid.

Note

If you ordered Windows 95 or NT on your system, the COM2 port is not available.

Xycom Controller

For VNHS with the AHIP6 board: If touchscreen is factory installed, the touchscreen is set up on the AUX port, making this port unavailable.

If you want to reconfigure the touchscreen to use the COM2 port, perform the following steps:

1. Disconnect the power.

2. Remove the lid.

3. Remove the touchscreen controller card (see Figure 3-18B).

J1 J2

JUMPERS

J7 J8 J9

Chapter Three - Installation

Note

TOUCH SCREEN

NTROL CONN.

Figure 3-18B. Touchscreen controller card

4. Reconfigure jumpers J1-J9. Position A = COM2. Position B

= PS/2 AUX. (Note: all jumpers must be in the A or B position).

5. Reinstall the touchscreen controller card.

6. Reboot the computer.

7. Using the touchscreen manual, do the following:

• Uninstall the UPDD Touch driver.

• Locate the Touch-Base Serial mode driver on the Xy-

com DOC CD.

• Follow the instructions on the readme.txt file for the se-

rial mode UPDD driver.

8. Replace the lid.

3500 Series Flat Panel Industrial PC

Specifying the Port

To reconfigure the touchscreen driver for COM2, uninstall the Universal Pointer Device Driver (UPDD).

To reinstall UPDD for serial mode:

1. Locate the Xycom Documentation CD.

2. Search the CD for Touch-Base touch drivers.

3. Locate the Touch Serial Mode folder.

4. Follow the installation instructions in the readme.txt file

Calibrating the Touchscreen

Depending upon the date of purchase, the Xycom Automation unit will have one of two possible touchscreen controllers:

• The Microtouch Controller P/N 114084

• The Xycom Controller P/N 140554

These controllers function similarly. However, the following sections require attention to the type of controller installed.

Microtouch Controller

If you need to recalibrate the touchscreen, refer to the sections in the touchscreen manual that explain calibrating the touchscreen and using the diagnostic utility.

Note

The touchscreen and controller are a matched pair calibrated at the factory.

Xycom Controller

If you need to recalibrate the touchscreen, run the Pointer Devices Control Panel applet. Select Help for details about calibrating. For best results, use the 25 point calibration setting with Start In At set to 0.

You need to calibrate the touchscreen if

• The cursor does not follow the movement of your finger or pen

• You adjust the size of the video image or change the video mode

Video Expansion

This section deals with the hardware expansion capability of the video controller chip in DOS applications.

It is not necessary to read this section if you are a Windows 95, Windows NT, or OS/2 user, do not plan to run DOS applications, and have not modified the default expansion mode in the BIOS setup menus.

Unlike a CRT, a flat panel display has a fixed horizontal and vertical resolution. There are many DOS video modes whose resolution is less than that of a flat panel display. To more efficiently make use of the flat panel display’s active area, it is necessary to employ an expansion technique that stretches the lower resolution information to fill the higher resolution of the display. For example, DOS defaults to VGA video mode 3+. This is an 80 column, 25 row text only screen whose effective resolution is 640 dots x 400 scan lines. Because of this, the 1024 x 768 display of the unit will be partially filled by the 640 x 400 resolution of this particular mode. By enabling the expansion function, these lower resolutions will better utilize the display by stretching the information in an attempt to fill the display. Operating systems such as Microsoft Windows 3.X, Windows 95, and Windows NT use display drivers to handle the different flat panel displays. Expansion is not necessary since there is a specific driver for each resolution.

Chapter Three - Installation

Note

Expansion does not add any resolution to the existing information; it simply stretches the information to better fit the display. Text and graphic screens can look somewhat grainy after expansion.

You can turn expansion off in the BIOS setup menus, or by executing an included utility program. See the table below for the three utility programs included to allow expansion to be turned on, turned off, and set back to the BIOS default state and what effect they have on the display.

Table 3- 1. 3515/3512KPM Video Expansion Options

Utility Mode Panel Type/Size

15" 12.1" TFT

EXP_ON.EXE Text Vert/Hor Vert/Hor Expansion On Graphics Vert/Hor Vert/Hor EXP_DEF.EXE Text Off Vert/Hor Expansion Default Graphics Off Off EXP_OFF.EXE Text Off Vert/Hor Expansion Off Graphics Off Off

Definitions:

Vert: Vertical only expansion is invoked Vert/Hor: Vertical and Horizontal expansion is invoked Expansion Default: The video BIOS default on power up

Text expansion cannot be turned off.

3500 Series Flat Panel Industrial PC

On a 1024 x 768 display, the stretching algorithm does not completely fill the display horizontally or vertically. You can achieve a greater vertical text expansion by changing to VGA mode 3* (see Note below). This is an 80 column, 25 row text mode with an effective resolution of 640 x 350. The 350 lines stretch better to fill the 768 line display.

The utility disk includes the MOD3_350.EXE utility, allowing you to switch to VGA mode 3*. The MOD3_400.EXE utility allows you to change the mode back to the DOS default of 3+.

Windows may come up with a blank screen when using Windows 3.X on a unit, with expansion turned on either through the BIOS setup m enus or using the E XP_ON .EXE utility .

There are two available options (second option being the best) to resolve this situation:

Note

• Press the

press any key to return to Windows. The Windows screen should appear.

• Turn off the expansion.

• Default to factory settings in the BIOS setup menus.

• Use the appropriate utility as shown in the Video Expansion Options table.

For further assistance, call Xycom Automation technical support at 1800-289-9266.

CTRL-ALT-DEL keys simultaneously. When the Windows message appears,

Mounting Considerations

This section describes issues you must address before placing the unit inside an enclosure. Consider the following points and precautions:

• Select an enclosure and place the unit to allow easy access to the ports.

• Account for the unit’s depth when choosing the depth of the enclosure.

• Provide a NEMA 4 seal by mounting the unit in an approved enclosure with a 14

gauge (0.075"/1.9mm thick) steel or (0.125"/3.2mm thick) aluminum front face.

• Mount the unit in an upright position.

• Place the unit at a comfortable working level.

• Consider locations of accessories such as AC power outlets and lighting (interior

lighting and windows) for installation and maintenance convenience.

• Prevent condensation by installing a thermostat-controlled heater or air conditioner.

• To allow for maximum cooling, avoid obstructing the airflow.

• Place any fans or blowers close to the heat generating devices. If using a fan, ensure

that outside air is not brought inside the enclosure unless a fabric or other reliable filter is used. This filtration prevents conductive particles or other harmful contaminants from entering the enclosure.

Note

Enclosures

Chapter Three - Installation

• Do not select a location near equipment that generates excessive electromagnetic in-

terference (EMI) or radio frequency interface (RFI) (equipment such as high power welding machines, induction heating equipment and large motor starters).

• Place incoming power line devices (such as isolation or constant voltage transform-

ers, local power disconnects, and surge suppressers) away from the unit.

• The proper location of incoming line devices keeps power wire runs as short as pos-

sible and minimizes electrical noise transmitted to the unit.

• Make sure the location does not exceed the unit’s shock, vibration, and temperature

specifications.

• Install in the panel in such a way as to ensure that it does not cause a hazard from

uneven mechanical loading.

• Avoid overloading the supply circuit

The systems are designed for installation within a clean and dry enclosure for both ordinary and hazardous locations. The front panel meets the requirements for Type 4, 4X, and 12 enclosures. The enclosure used for Class I hazardous locations should have a minimum rating of Type 12 (NEMA 12, IP 5X). However, Type 4 (IP 6X) enclosures are strongly recommended.

The floppy disk/keyboard port access door must be closed and latched at all times to maintain a proper seal against water and dust.

Panel flatness and rigidity are important to maintain a proper panel seal. If you are using non-metal type enclosures, such as plastic or fiberglass, install a rigid metal stiffener behind the front panel. Failure to do so may result in an inadequate panel seal due to flexure of the front panel material between the stud mounts. Tighten the nuts on the mounting studs to 25-inch pounds.

The requirements for enclosure fittings, conduit, and wiring vary according to the specific rating of the location and the type of flammable or combustible material involved. Those requirements are beyond the scope of this document and it is the responsibility of the customer to ensure that their installation is compliant with codes and regulations that apply to their specific location. Reference NFPA 70, Article 500 for specific regulations in the United States.

System Power

On the average, the temperature within the system is 7-10°C higher than that outside the enclosure. When the ambient (exterior) temperature reaches 42°C, the system’s power supply will begin to derate at a rate of 3.25 watts per increase of 1°C.

Warning

The unit is rated to work at temperatures up to 50°C (at 50ºC, no more than 100 watts of expansion can be added to the system).

Refer to the table below for more information.

3500 Series Flat Panel Industrial PC

Voltage Available Current

AHIP6+

+3.3 VDC 10.6A

+5 VDC 10.6A

+12 VDC 4.88A

-12 VDC 0.76A

-5 VDC 0.50A

Total expansion power not to exceed 100 watts

Combined 3.3V and 5V expansion is 10.6A

b b

It is a good idea to use isolation transformers on the system’s incoming AC power line. An isolation transformer is especially desirable in cases where heavy equipment is likely to introduce noise onto the AC line. The isolation transformer can also serve as a step-down transformer to reduce incoming line v oltag e to a desired lev el. The transform er should have a sufficient power rating (units of volt-am peres) to supply the load adequately .

Proper grounding is essential to all safe electrical installations. Refer to the relevant Federal, State, Provincial, and local electric codes which provide data such as the size and types of conductors, color codes and connections necessary for safe grounding of electrical components. The code specifies that a grounding path must be permanent (no solder), continuous, and able to safely conduct the ground-fault current in the system with minimal impedance (minimum wire required is 18 Awg, 1 mm).

Observe the following practices:

• Separate ground wires (P.E. or Protective Earth) from power wires at the point of

entry to the enclosure. To minimize the ground wire length within the enclosure, locate the ground reference point near the point of entry for the plant power supply.

• All electrical racks or chassis and machine elements should be Earth Grounded in in-

stallations where high levels of electrical noise are expected. Ground the chassis with a ground rod or attach to a nearby Earth structure such as a steel support beam. Each different apparatus should be connected to a single Earth Ground point in a “star” configuration with low impedance cable. Scrape away paint and other nonconductive material from the area where a chassis makes contact with the enclosure. In addition to the ground connection made through the mounting bolt or stud, use a one-inch metal braid or size #8 AWG wire to connect between each chassis and the enclosure at the mounting bolt or stud.

Excessive Heat

The system withstands operating temperatures from 0º to 50º C (32º to 122º F). To keep the temperature in the specified range, the air at the base of the system must not exceed 50°C. Allocate proper spacing between internal components installed in the enclosure.

When the air temperature is higher than 50ºC in the enclosure use a fan or air conditioner.

Electrical Noise

Electrical noise is seldom responsible for damaging components, unless extremely high energy or high voltage levels are present. However, noise can cause temporary malfunctions that can result in hazardous machine operation in certain applications. Noise may be present at certain times, may appear between widely spread intervals, or in some cases, may exist continuously.

Noise commonly enters through input, output, and power supply lines and may also be coupled through the capacitance between these lines and the noise signal carrier lines. This usually results from the presence of high voltage or long, close-spaced conductors. When control lines are closely spaced with lines carrying large currents, the coupling of magnetic fields can also occur. Use shielded cables to help minimize noise. Potential noise generators include switching components, relays, solenoids, m otors, and motor starters.

Refer to the relevant Federal, State, Provincial, and local electric codes. These codes provide data such as the size and types of conductors, color codes and connections necessary for safe grounding of electrical components. It is recommended that the high voltage and low voltage cabling be separated and dressed apart. In particular, the AC cables and switch wiring should not be in the same conduit with all communication cables.

Chapter Three - Installation

Line Voltage Variation

The unit’s power supply is built to operate with output voltage ranges of 100-120 VAC and 200-240 VAC with an AC power supply and 19-30 VDC with a DC power supply, and still allow the system to function within its operating margin. As long as the incoming voltage is adequate, the power supply provides all the logic voltages necessary to support the processor, memory, and I/O.

In cases in which the installation is subject to unusual AC line variations, use a constant voltage transformer to prevent the system from shutting down too often. However, a first step toward the solution of the line variations is to correct any possible feed problem in the distribution system. If this correction does not solve the problem, use a constant voltage transformer.

The constant voltage transformer stabilizes the input voltage to the unit by compensating for voltage changes at the primary in order to maintain a steady voltage at the secondary. When using a constant voltage transformer, check that the power rating is sufficient to supply the system.

Creating a Power Cable

This section describes how to create both an AC and a DC power cable.

AC Power Cable

A power cable must be created to supply power to the unit. The materials needed are:

• A three-position power connector (supplied)

• A braid/foil shielded power cable, terminated at power source end, with three 18 (1.0

mm), 16 (1.3 mm), or 14 (1.6 mm) Awg solid or stranded copper wires, rated 80ºC or better

3500 Series Flat Panel Industrial PC

Perform the following steps to create and attach the cable:

1. Cut wire cable to the desired length.

2. Strip 0.25-inch (6 mm) of insulation from the end of the conductor wire. No bare

wire should be exposed when the cable is connected to the workstation.

3. Tin the wire ends with solder if using stranded wire. This will keep the wire

from fraying.

Figure 3-19. 3515 AC Power Connector.

Warning

When inserting the wire ends of the power cable into the block plug, be sure there is no exposed wire. Trim the wire ends of the cable or cut a new cable if necessary.

Figure 3-20. Internal View of 3515 AC Power Connector

4. Insert the three wire ends of the power cable into the hole of the connector plug.

Bend the Protective Earth ground (PE) wire, the neutral (N) wire, and the line (L) wire around the corresponding screw. Be sure that no bare wires are exposed.

5. Tighten the three screws above the wires to hold them firmly in place.

Never tighten the three screws of the block plug when the cable is connected to a power source. The screws are conductive and have full contact with the cable wire.

Warning

Chapter Three - Installation

6. Use the screw provided to secure and strain-relief the power cable inside the con-

nector. Plug the power cable into the power supply located on the side of the unit.

7. Once the power cable and other optional interface cables are installed, installation

is complete.

Note

When disconnecting the power cord from the unit, be sure to completely loosen the two securing screws on the retainer bracket.

Cable Retainer Bracket

Once you have created the power cable, attach the retainer bracket that secures the cable connector to the unit. You must use this retainer bracket in hazardous locations.

Warning

Absence of this bracket can allow a power connector to become disengaged. An explosion could result if this occurs in the presence of a hazardous environment.

1. Plug the completed cable into the system’s power supply.

2. Place the retainer bracket over the connector so that the shorter sides wrap around

the connector and the screw holes on the large flange line up with those on the case.

3. Insert the two 6-32 screws and tighten to the standard torque (11-in/lb).

Figure 3-21. 3515/3512KPM Cable Retainer Bracket

Warning

The connector retainer bracket must be placed around the cable connector and screwed into the 3515/3512KPM case.

Mounting the Unit

The system’s rugged design allows it to be installed in most industrial environments. The unit is generally placed in a NEMA 4/4X/12 enclosure to protect against contaminants

3500 Series Flat Panel Industrial PC

such as dust, moisture, etc. Metal enclosures also help minimize the effects of electromagnetic radiation that may be generated by nearby equipment.

Once the conditions in the preceding sections have been met, follow the instructions below to mount the unit:

1. Locate a position for your system that meets the specifications required (see previous

sections and Appendix A).

2. Cut the hole according to the cutout dimensions in Figure 3-22.

3. Make sure the area around the cutout is clean and free from metal burrs.

4. Install the unit.

5. Attach the power cable making sure that the 3515/3512KPM enclosure is grounded

through the power cable.

6. On a system with an AC power supply, attach the connector retainer bracket; on a system

with a DC power supply, attach the aluminum p-clamp.

7. Implement the proper grounding techniques. Establish a ground path from the

3515/3512KPM chassis to the enclosure chassis. A 6-32 threaded ground point ( is provided on the left back of the front panel (as viewed from the front) of the unit. There is also an internal ground point (

) hole

8. Tighten the 14-#10 nuts to 27 inch pounds (3.0456 Newton-meters).

If you use the CD-ROM, use of controls, adjustments, or the performance of procedures other than those specified herein, may result in hazardous radiation exposure.

System Cutout Dimensions

Caution

Figure 3-22. System Cutout Dimensions

Hazardous Locations Installations

Xycom Automation designed the systems with the intention of meeting the requirements of Class I, Division 2 Hazardous Locations applications. Division 2 locations are those locations that are normally non-hazardous, but potentially hazardous should an accident expose the area to flammable vapors, gases or combustible dusts.

These systems are non-incendiary dev ices. They are not intrinsically safe and should never be operated within a Division 1 (normally hazardous) location when installed as described here. Nor should any peripheral interface device attached to these system s be located within Division 1 locations unless approved and/or certified diode barriers are placed in series with each individual signal and DC power line. Any such installations are beyond the bounds of Xycom Automation design intent. Xycom Automation accepts no responsibility for installations of this equipment or any devices attached to this equipment in Division 1 locations.

Note

It is the customer’s responsibility when adding additional cards that they meet operating conditions for Class I, Division 2 hazardous locations.

Chapter Three - Installation

It is the responsibility of the customer to ensure that the product is properly rated for the location. If the intended location does not presently have a Class, Division, and Group rating, then users should consult the appropriate authorities having jurisdiction in order to determine the correct rating for that Hazardous Location.

In accordance with Federal, State/Provincial, and Local regulations, all hazardous location installations should be inspected by the appropriate authority having jurisdiction prior to use. Only technically qualified personnel should install, service, and inspect these systems.

Warning

Suitable for use in Class I, Division 2 Groups A, B, C, and D, and Class II, Division 2, Groups F and G hazardous locations or non-hazardous locations only.

Warning - Explosion Hazard

Substitution of components may impair suitability for Class I, Class II, Division 2.

Advertissement Risque D’ Explosion

La substitution de composants peut rendre ce materiel inacceptable pour les emplamements de classe I, II, Division 2.

3500 Series Flat Panel Industrial PC

Do not disconnect equipment unless the power has been switched off or the area is known to be non-hazardous.

Advertissement Risque D’ Explosion

Avant de deconnecter l’equipment, coupler le courant ou s’assurer que l’emplacement est designe non dangereux.

When in hazardous locations, turn off power before replacing or wiring modules.

Advertissement Risque D’ Explosion

Dans les situations hasardees, couper la courant avant de remplacer ou de cabler les modules.

Warning - Explosion Hazard

Definitions

Warning

To maintain a safe condition, do not use an external keyboard or mouse or USB port devices when the unit is operating in a hazardous environment.

The following Class and Division explanations are derived from Article 500 (Sections 5 and 6) of the United States National Fire Protection Agency National Electric Code (NFPA 70, 1990). They are not complete and are included here only for a general description for those not familiar with generic hazardous locations’ requirements.

Persons responsible for the installation of this equipment in Hazardous Locations are responsible for ensuring that all relevant codes and regulations related to location rating, enclosure, and wiring are met.

Class I Locations

Class I locations are those in which flammable gases or vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures.

Class II Locations

Class II locations are those that are, or may become, hazardous because of the presence of combustible dust.

Chapter Three - Installation

Division 1 Locations

A Division 1 location is one in which flammable or ignitable gasses, vapors, or combustible dusts and particles can exist due the following conditions:

• Normal operating conditions.

• Because of repair, maintenance conditions, leakage, or where mechanical failure or

abnormal operation of machinery or equipment might release or cause explosive or ignitable mixtures to be released or produced.

• Combustible dusts of an electrically conductive nature may be present in hazardous

quantities.

Note

Xycom Automation 3515/3512KPM systems are not suitable for installation within Division 1 locations.

Note

Electrical equipment cannot be installed in Division 1 locations unless they are intrinsically safe, installed inside approved explosion-proof enclosures, or installed inside approved purged and pressurized enclosures.

Division 2 Locations

• Class I volatile flammable liquids or flammable gasses are handled, processed, or

used, but confined within closed containers or closed systems from which they can escape only in cases of accidental rupture or breakdown of such enclosures or systems, or in case of abnormal operation of equipment.

• Ignitable concentrations of Class I vapors or gasses are normally prevented by posi-

tive mechanical ventilation, but which may become hazardous due to mechanical failure of those ventilation systems.

• Location is adjacent to a Division 1 location.

• Class II combustible dust is not normally in the air in quantities sufficient to produce

explosive or ignitable mixtures. Dust accumulations are normally insufficient to interfere with normal operation of electrical equipment or other apparatus. Combustible dust may be in suspension in the air as a result of the following: infrequent malfunctioning of handling or processing equipment; combustible dust accumulations on, or in the vicinity of electrical equipment; may be ignitable by abnormal operation or failure of electrical equipment.

Groups

All electrical equipment that is approved for use in hazardous locations must include a group rating. Various flammable and combustible substances are divided into these groups as a function of their individual maximum experimental safe gap (MESG), explosion pressure, and ignition temperature.

Component temperatures and the potential for spark based upon voltage, current, and circuit characteristics, within electrical equipment, will determine what the equipment

3500 Series Flat Panel Industrial PC

group rating will be. A device approved for installation within Class I, Group A locations may also be used in Groups B, C, or D.

Approved Class I equipment may not be suitable for Class II installations. Class I includes Groups A, B, C, and D. Class II includes Groups F, and G.

Power Sw itch

The systems do not have a power switch. The amount of input power required by these systems classifies a power switch as an incendiary device because the voltage and current across the make/break device are capable of creating a spark.

Hazardous locations’ regulations require that a power switch rated for ordinary locations may be used if it is located in an area specified as non-hazardous. However, limits in cable length between the workstation and the power switch may apply. Otherwise the switch must be compliant with Class I, Division 1 requirements (intrinsically safe). These switches are built in a manner that prevents the possibility of a spark when contacts are made or broken.

Note

Use suitable UL listed and/or CSA Certified Class I, Division 1 switches in hazardous locations. These switches are available from a wide number of sources. It is the responsibility of the customer to ensure that the power switch selected for their installation has the correct hazardous locations rating for the location in which it is installed.

Cable Connections

Division 2 hazardous locations’ regulations require that all cable connections be provided with adequate strain relief and positive interlock. USB connections can never be used in hazardous location installations, because USB connectors do not provide adequate strain relief. Never connect or disconnect a cable while power is applied at either end of the cable.

All communication cables should include a chassis ground shield. This shield should include both copper braid and aluminum foil. The D-sub style connector housing should be a metal conductive type (e.g., molded zinc) and the ground shield braid should be well terminated directly to the connector housing. Do not use a shield drain wire.

The outer diameter of the cable must be suited to the inner diameter of the cable connector strain relief in order to ensure that a reliable degree of strain relief is maintained. Always secure the D-Sub connectors to the 3515/3512KPM workstation-mating connectors via the two screws located on both sides.

Warning

Never connect or disconnect the communication cables while power is applied at either end of the cable. This may result in an incendiary spark. Permanent damage to the workstation communication components may occur.

Operation and Maintenance

The systems have been designed for compliance with relevant spark ignition tests. However, please note that the workstation front panel contrast adjustment tactile switches and keyboard connector are the only make/break components intended to be exercised by the operator in the course of normal operation.

To maintain a safe condition, never use an external keyboard or m ouse or USB port devices when the unit is operating in a hazardous environment.

Always observe the following rules with respect to hazardous location installations:

1. Always install the workstations within an enclosure suitable for the specific applica-

tion. General-purpose enclosures may be acceptable for Class I applications but are never acceptable for Class II applications. Type 4 (IP 65) enclosures are recommended even when not required by regulations.

2. If present, keep enclosure doors or openings closed at all times, to avoid the accu-

mulation of foreign matter inside the workstation.

Chapter Three - Installation

Warning

3. Never subject the unit to any installation or service procedures unless power is re-

moved and the area is known to be non-hazardous. This includes the installation or removal of power cables, communication cables, or removal of the rear cover of the unit.

Only technically qualified service personnel should perform all installation and service. These workstations are designed to require no service in the course of normal operation by an operator.

Safety A gency A pprov al

The Xycom Automation systems are designed to meet the following standards:

• Underwriters Laboratories Inc., UL 1604 Standard for Safety

Electrical equipment for use in Class I and Class II, Division 2, locations

• Underwriters Laboratories Inc., UL 1950, Information Technology Equipment

• Canadian Standard Association, Specification C22.2 No. 213-M1987

Non-incendiary electrical equipment for use in Class I, Division 2 hazardous locations

• Canadian Standards Association, Specification C22.2 No. 950

Information Technology Equipment

• EN 60950, Information Technology Equipment

3500 Series Flat Panel Industrial PC

Chapter Four – Keypad Utility Program

The Keypad Utility lets users redefine all keypad keys with new scan codes using utility software. Use an external full-stroke PC/AT keyboard to access the utility (you cannot redefine the keyboard).

Note

The keypad switch arrays are disabled while the k ey pad utility is running.

Loading the Keypad Utility

Note

You need MS-DOS 3.2 or higher to run the keypad utility. It will not work if you are running Windows 95 or Windows NT. However, the keypad utility will run under Windows 95 in DOS mode.

You can run this utility directly from the disk or copy it onto your hard drive. To run the keypad utility from the disk, change the directory to the appropriate drive and type kputil. To load the utility onto your hard drive, create a subdirectory for the files, and copy all the files on the disk into that subdirectory. Enter the subdirectory and type kputil.

Using the Keypad Utility

The keypad utility uses a menu bar and pull-down menu system. All menu bars are displayed across the top of the screen. “Xycom Automation KP Utility” and the current menu titles are shown at the bottom of the screen (see Figure 4-1).

A full-stroke keyboard is needed to enter keystrokes while recording a new key macro, editing an existing macro, and entering utility commands. You can redefine all keys on the keypads. While the utility is running, the keypads are disabled.

Dialog boxes appear for user prompts and to display error and user advice messages. Two keys allow you to exit the menus:

ESC moves to the previous menu or out of the utility from the Main Menu.

•

F1 returns to the current menu headings in some of the menus where Exit can be cho-

•

sen to exit this menu.

Keys specific to each menu are shown at the bottom of each screen.

Startup

Type kputil to run the full keypad utility.

Utility Batch Mode

You can also use a batch file to reprogram keypads. This feature is useful if you wish to reprogram many units with customized keypad macros without having to enter the full keypad utility for each unit. Once the full utility has been used to create and save keypad macros, the files containing these macros can be included on a disk with the keypad utility and then used to reprogram other units from a batch file.

The command keypad filename runs the keypad utility batch mode. “Filename” is the file containing the new keypad macros. The filename extension must be included. For example, in a batch file, the command keypad def3512kpm.pkm would reprogram the keypad on the 3512KPM with default values for the numeric keypad. After programming, the system will reboot.

Main Menu

Chapter Four–Keypad Utility Program

Figure 4-1 illustrates the Main Menu.

Exit Files Macros Upload Download Utilities

Xycom Automation KP Utility: MAIN L-Arrow, R-Arrow, Enter

Figure 4-1. Main Menu

Exit

Exit closes open files and exits the utility. ESC can also be used for this purpose and for exiting the other menus.

3500 Series Flat Panel Industrial PC

Files Menu

You can save files containing keypad macro sets (a macro for each key) on disk, and then loaded them into memory to view, edit, teach, or download to the keyboard controller. Some of these files may be included in the utility package for use in reconfiguring the keypads for different software packages, and as templates for defining completely new keypad macro sets.

When you choose File, a pull-down menu will display the following choices: Open, Close, Save, Save As, Delete, and Exit. The following table describes the menu commands.

Command Description

Open Opens a file that contains a macro set for the keypad and loads the con-

Close Clears the macro set from memory and closes the file from which they

Save Copies the macro set from memory back into its original file. The original

Save As Creates a new file under the specified name and copies the macro set

Delete Deletes a file. Exit Returns to the Main Menu.

tents into memory. Any macro set in memory is overwritten. Once loaded, the macro set is available to edit, view, teach, or download to the keyboard controller.

came.

file contents are overwritten.

from memory into it. For example, to define different sets of codes, save each set under a different name and download the one you wish to use.

Macros Keypad Type Menu

When you select Macros, a pull down menu displays and provides the following choices: Function Keys, Alpha Keys, and Exit. Also, another pull down menu displays the following choices once the Macros menu is chosen: Exit, View, Teach, and Edit.

You must have a macro file in memory before the Macros Menu is available. To load a macro file, open a file or upload macros.

Command Description

Function Keys Selects the function keys on the keypad to either view, edit, or teach. Alpha Keys Selects the alpha keys on the keypad to either view, edit, or teach. Exit Returns to the main menu.

Note

Chapter Four–Keypad Utility Program

Macros Edit Menu

Command Description

Exit Returns to the Main Menu. View Allows you to view, but not edit, the macro for the selected key. When View is chosen,

the Exit option is displayed on the menu bar and a graphic representation of the chosen keypad is shown. Select Exit from the View Menu to return to the Macros Menu. To select a key to view, use the arrow keys to position the cursor on the desired key and press displays each keycode as the keys it represents on the full-stroke keyboard. Special labels are used for certain keys (e.g., Spc for space bar, UAr for up arrow, and bk for the break code prefix). The code line is displayed in either Hex or decimal. There is a one-to-one correspondence between the ASCII and code lines.

While viewing the macro, the menu bar displays two options: Exit and Hex/Decimal. Exit returns to the View Menu, while Hex/Decimal toggles between displaying the macro in hex or decimal format. When Hex is chosen, the keycodes are displayed as hexadecimal value scan codes. When Decimal is chosen, the keycodes are displayed as the decimal equivalent of the hex codes.

For example, the macro abc would be displayed as 1C F0 1C 32 F0 32 21 F0 21 in hex, and 28 240 28 50 240 50 33 240 33 in decimal.

Teach Allows you to record up to 105 keystrokes in a macro. When selected, a graphic rep-

resentation of the keypad currently in memory displays. Menu bar choices are Exit, ASCII/Hex/Decimal, and Click ON/OFF. Exit returns to the Macros menu. ASCII/Hex/Decimal specifies the format to display the keystrokes as they are entered. Default is ASCII. Click is not supported.

To select a key to define, use the arrow keys to position the cursor on the desired key and press ternal full-stroke keyboard in a macro assigned to the chosen key. As the keys are entered, they are displayed using the chosen format. to the Teach Menu, so you cannot record the in a macro by using the editor. Changes made to the macros in the Teach Menu are not programmed until you select Download.

ENTER. The macro is displayed as two lines: ASCII and code. The ASCII line

ENTER. After you select a key, the utility records every keystroke on the ex-

ESC stops recording and returns

ESC key. However, ESC can be included

Command Description

Edit Displays a graphic representation of the keypad in memory and a menu bar displaying

Exit, Click, and ON/OFF. Exit returns to the Macros menu. Click is not supported. To select a key to edit, use the arrow keys to position the cursor on the desired key and

ENTER.

press In edit mode, the macro is displayed as two lines. The top line (the edit line) displays

the macro in either hex or decimal format and is the line in which the editing takes place. The bottom line displays the macro in ASCII format; it is not user configurable. This line keeps track of which part of the macro you are editing, and is updated by the utility as editing takes place.

The insert, delete, and cursor control keys are active for editing. When a key is selected from the Edit Macro option, the menu bar displays the following choices: Exit, Cut, Copy, Paste, Codes, Hex/Decimal, and I/O (Insert/Overtype). The macro for the chosen key is also displayed.

Cut deletes a sequence of scan codes from the macro. To select a section to cut:

1. Place the cursor on the first character to cut.

2. Press

3. Press

F1 and select CUT. ENTER. Cut should still be highlighted, but the cursor will appear on the Edit

line. Move the cursor on the last character to cut and press

ENTER.

3500 Series Flat Panel Industrial PC

The last character of every macro is the end of the macro (EOM) and cannot be deleted.

Copy copies a sequence of scan codes from the macro into memory. To select the section to copy:

1. Place the cursor on the first character to copy. Press F1 and select Copy.

2. Press

3. Move the cursor on the last character to copy and press The copied item does not appear on the screen until you select Paste inserts a sequence of scan codes (which were saved in memory using Copy)

into the macro. To paste a sequence of scan codes that were previously copied, position the cursor where you want the text to appear and then press then press Codes section in this chapter for a complete code listing. Hex/Decimal toggles between displaying the scan codes in Hex and Decimal formats. Insert toggles between insert and overtype mode.

ENTER. Copy should still be highlighted, but the cursor will appear on the

Edit line.

ENTER. Codes displays a table of keys and their scan codes in Hex. See the

Upload Menu

Use the Upload Menu to choose which data to load. Choices in this menu are: Combo Keypad, Keypad Version, and Exit.

ENTER.

Paste.

F1. Select Paste and

Command Description

Combo Keypad Commands the keyboard controller to send its entire macro set for the keypad. Keypad Version Commands the keyboard controller to send its firmware revision number. Exit Returns to the Main Menu.

Note

Only one macro set may reside in memory at one time.

A checksum will be calculated during transmission. If an error occurs, an error message will display.

Download Menu

Note

When you select Download, any macro set previously programmed is overwritten.

Download sends the set of keypad macros to the keyboard controller. The macro set must reside in memory before it can be downloaded. A checksum is calculated during transmission and an error message displays if an error occurs.

As the macro is sent, the keyboard controller programs its non-volatile memory with the new macros that become the new key definitions for the keypad. After programming the system will reboot.

Utilities Menu

When Utilities is selected, a menu bar displays four choices: Func Lock ON, Func Lock OFF, Clear EEPROM, and Exit.

Command Description

Func Lock ON Not available on the 3512KPM or 3515KPM. Func Lock OFF Not available on the 3512KPM or 3515KPM. Factory Default Reprograms the keypad macros to the factory default settings. After

Exit Returns to the Main Menu.

Keypad Scan Codes

The utility’s default keypad keycodes are listed in the following table.

Chapter Four–Keypad Utility Program

completion, the system will reboot.

Default Keypad Keycodes

3512KPM F/A Key LED Off (Function Mode) F/A Key LED On (Alpha Mode)

Description of Key

PF1 / A F21 14 05 F0 05 F0 14 A 1C F0 1C PF2 / B F22 14 06 F0 06 F0 14 B 32 F0 32 PF3 / C F23 14 04 F0 04 F0 14 C 21 F0 21 PF4 / D F24 14 0C F0 0C F0 14 D 23 F0 23 PF5 / E F25 14 03 F0 03 F0 14 E 24 F0 24 PF6 / F F26 14 0B F0 0B F0 14 F 2B F0 2B PF7 / G F27 14 83 F0 83 F0 14 G 34 F0 34 PF8 / H F28 14 0A F0 0A F0 14 H 33 F0 33 PF9 / I F29 14 01 F0 01 F0 14 I 43 F0 43 PF10 / J F30 14 09 F0 09 F0 14 J 3B F0 3B F1 / K F1 05 F0 05 K 42 F0 42 F2 / L F2 06 F0 06 L 4B F0 4B F3 / M F3 04 F0 04 M 3A F0 3A F4 / N F4 0C F0 0C N 31 F0 31 F5 / O F5 03 F0 03 O 44 F0 44 F6 / P F6 0B F0 0B P 4D F0 4D F7 / Q F7 83 F0 83 Q 15 F0 15 F8 / R F8 0A F0 0A R 2D F0 2D F9 / S F9 01 F0 01 S 1B F0 1B F10 / T F10 09 F0 09 T 2C F0 2C F11 / U F11 12 05 F0 05 F0 12 U 3C F0 3C F12 / V F12 12 06 F0 06 F0 12 V 2A F0 2A F13 / W F13 12 04 F0 04 F0 12 W 1D F0 1D F14 / X F14 12 0C F0 0C F0 12 X 22 F0 22 F15 / Y F15 12 03 F0 03 F0 12 Y 35 F0 35 F16 / Z F16 12 0B F0 0B F0 12 Z 1A F0 1A

Keyboard Equivalent

Make Codes

Break Codes Keyboard

Equivalent

Make Codes

Break Codes

3500 Series Flat Panel Industrial PC

3512KPM F/A Key LED Off (Function Mode) F/A Key LED On (Alpha Mode)

F17 / : F17 12 83 F0 83 F0 12 : 12 4C F0 12 F0 4C F18 / / F18 12 0A F0 0A F0 12 / 4A F0 4A F19 / \ F19 12 01 F0 01 F0 12 \ 5D F0 5D F20 / * F20 12 09 F0 09 F0 12 * 12 3E F0 12 F0 3E PF11 / ( F31 11 05 F0 05 F0 11 ( 12 46 F0 12 F0 46 PF12 / ) F32 11 06 F0 06 F0 11 ) 12 45 F0 12 F0 45 PF13 / ? F33 11 04 F0 04 F0 11 ? 12 4A F0 12 F0 4A PF14 / ^ F34 11 0C F0 0C F0 11 ^ 12 36 F0 12 F0 36 PF15 / % F35 11 03 F0 03 F0 11 % 12 2E F0 12 F0 2E PF16 / $ F36 11 0B F0 0B F0 11 $ 12 25 F0 12 F0 25 PF17 / @ F37 11 83 F0 83 F0 11 @ 12 1E F0 12 F0 1E PF18 / < F38 11 0A F0 0A F0 11 < 12 41 F0 12 F0 41 PF19 / > F39 11 01 F0 01 F0 11 > 12 49 F0 12 F0 49 PF20 / ~ F40 11 09 F0 09 F0 11 ~ 12 0E F0 12 F0 0E CTRL CTRL 14 F0 14 CTRL 14 F0 14 SHIFT SHIFT 12 F0 12 SHIFT 12 F0 12 ESC ESC 76 F0 76 ESC 76 F0 76 ALT ALT 11 F0 11 A LT 11 F0 11 TAB TAB 0D F0 0D TAB 0D F0 0D DEL DEL E0 12 E0 71 E0 F0 71 E0 F0 12 DEL E0 12 E0 71 E0 F0 71 E0 F0 12 F/A SPACE SPACE 29 F0 29 SPACE 29 F0 29 BACK

SPACE 1 1 16 F0 16 1 16 F0 16 2 2 1E F0 1E 2 1E F0 1E 3 3 26 F0 26 3 26 F0 26 4 4 25 F0 25 4 25 F0 25 5 5 2E F0 2E 5 2E F0 2E 6 6 36 F0 36 6 36 F0 36 7 7 3D F0 3D 7 3D F0 3D 8 8 3E F0 3E 8 3E F0 3E 9 9 46 F0 46 9 46 F0 46 . . 49 F0 49 . 49 F0 49 0 0 45 F0 45 0 45 F0 45 = = 55 F0 55 = 55 F0 55 PgUp PgUp E0 12 E0 7D E0 F0 7D E0 F0 12 PgUp E0 12 E0 7D E0 F0 7D E0 F0 12 up arr up arr E0 12 E0 75 E0 F0 75 E0 F0 12 up arr E 0 12 E0 75 E0 F0 75 E0 F0 12 + + 79 F0 79 + 79 F0 79 left arr left arr E0 12 E 0 6B E0 F0 6B E0 F0 12 lef t arr E0 12 E0 6B E0 F0 6B E0 F0 12 HOME HOME E 0 12 E0 6C E 0 F0 6C E 0 F0 12 HOME E0 12 E0 6C E0 F0 6C E0 F0 12 right arr right arr E0 12 E0 74 E0 F0 74 E0 F0 12 right arr E 0 12 E 0 74 E0 F0 74 E0 F0 12 PgDn PgDn E0 12 E0 7A E0 F0 7A E0 F0 12 PgDn E0 12 E 0 7A E0 F0 7A E0 F0 12 down arr down arr E0 12 E0 72 E0 F0 72 E0 F0 12 down arr E0 12 E0 72 E0 F0 72 E0 F0 12

- - 7B F0 7B - 7B F0 7B ENTER ENTER 5A F0 5A ENTER 5A F0 5A END END E0 12 E0 69 E0 F0 69 E0 F0 12 END E0 12 E0 69 E0 F0 69 E0 F0 12 Left Start Mouse click

Explorer Mouse cli ck

BACK SPACE

(windows start menu)

(windows pop-up

66 F0 66 BACK

SPACE

E0 12 E0 1F E0 F0 1F E0 F0 12 E0 12 E0 1F E0 F0 1F E0 F0 12

E0 12 E0 2F E0 F0 2F E0 F0 12 E0 12 E0 2F E0 F0 2F E0 F0 12

66 F0 66

Chapter Four–Keypad Utility Program

3512KPM F/A Key LED Off (Function Mode) F/A Key LED On (Alpha Mode)

menu)

NOTES:

• F11-F20 = SHIFT F1-F10

• F21-F30 = CTRL F1-F10

• F31-F40 = ALT F1-F10

• END, LEFT START, and EXPLORE keys are only available for 3515KPM units.

Note

If you make any changes to your keypad and want to set it back to the default settings, open the pkm file for your unit (e.g., 3512KPM.PKM for 3512KPM” from the File/Open menu and then download it from the download menu. Do not save any changes to the default files.

Chapter Five - Maintenance

The 3500 series was designed to withstand the harsh environment of the factory floor. Routine maintenance can help keep your unit in good operating condition. Preventive maintenance consists of several basic procedures that significantly reduce the chance of system malfunction. Schedule preventive maintenance along with the regular equipment maintenance to minimize downtime.

Preventive Maintenance

Following are preventive measures you can take:

• Clean the monitor screen using a nonresidue cleaner such a mild window cleaning

solution or CRT screen cleaner. Take care not to scratch or mar the screen face.

• Clean or change the fan filter periodically to ensure that the air circulating in the unit

is clean. Wash the filter with warm water and dish soap, and let it air dry. Do not scrub the filter, and do not re-install it into the unit until it is completely dry.

• Base your maintenance schedule on the operating environment of the system (i.e., if

the area is dusty, you should schedule maintenance more often than if it is a dry, clean area). Check the filter often to determine if it needs to be changed ahead of schedule.

• Remove dust and dirt from PC components. If dust builds up on heat sinks and cir-

cuitry, an obstruction of heat dissipation could cause the unit to malfunction. If dust reaches the electronic boards, a short circuit could occur.

• Check the connections to I/O modules, especially in environments where shock

could loosen the connections. Check to see that all plugs, sockets, terminal strips, and module connections are secure.

• Remove unnecessary articles, such as drawings or manuals, from the unit. They can

obstruct air flow and create hot spots, which causes the system to malfunction.

• Do not place noise generating equipment near the 3515.

• Stock spare parts to minimize downtime resulting from part failure. The spare parts

stocked should be 10 percent of the number of each unit used. The main CPU cards should have one spare each. Each power supply should have a back-up. In certain applications where immediate operation of a failed system is required, you may need to stock an entire spare computer module see figure 5-6, Spare Parts List.

• Replace the module with the correct type. If the new module solves the problem but

the failure recurs, check for inductive loads that may be generating voltage and current spikes and may require external suppression.

Chapter Five - Maintenance

Xycom Recommended Hard Drive Preventative Maintenance

Xycom Automation has recognized that hard drive failures may begin to increase an average of four to five years into the life of most computers used in industrial applications.

3500 Series Flat Panel Industrial PC

Therefore, it is our recommendation as a preventative maintenance measure that all hard drives used in these types of applications be replaced before the four to five year time period to avoid any down time related to hard drive failure.

The purpose of this message is to merely bring this to our customer’s attention, to offer alternative solutions, and to provide all of our customers with the excellent service they deserve.

Any questions regarding this issue may be directed to our support center at

support@xycom.com.

Please note Xycom recommends frequent back ups of your hard drive, especially before beginning any preventative maintenance procedures.

Fuse Replacement

The unit has no accessible fuse. Return the unit to Xycom Automation for fuse replacement.

Fan Filter Replacement

To change the fan filter, remove the grill and filter as illustrated in the figure below. Clean or replace the filter and snap the assembly back into position.

Do not operate the unit without a fan filter. Dust build-up could cause the unit to malfunction.

Figure 5-1. Fan Assembly

Caution

Chemical Compatibility

Certain combinations of chemical environments, temperature, and stress can adversely affect parts made from thermoplastic resin. For this reason material that may come in

Chapter Five - Maintenance

contact with the unit should be carefully evaluated under end-use conditions for compatibility. You should also follow the use and compatibility recommendations of the material manufacturer. The table below lists general, chemical compatibility guidelines.

Figure 5-2. Chemical Compatibility

Chemical Class Effects

Acids No effect under most common conditions of concentration and

temperature.

Alcohols Generally compatible at low concentration and room

temperature. Higher concentrations and elevated temperatures result in etching and attack evidenced by decomposition.

Alkalis Generally compatible at low concentration and room

temperature. Higher concentrations and elevated temperatures result in etching and attack evidenced by

decomposition. Aliphatic Hydrocarbons Generally compatible Amines Surface crystallization and chemical attack. Avoid. Aromatic Hydrocarbons Partial solvents and severe stress cracking agents. Avoid. Detergents and Cleaners Mild soap solutions are compatible. Strong alkaline materials

should be avoided. Esters Causes severe crystallization. Partial solvents. Avoid. Greases and

Oils Halogenated

Hydrocarbons Ketones Causes severe crystallization and stress cracking. Partial

Silicone Oil and Greases Generally compatible up to 85ºC (185º F). Some contain

Pure petroleum types generally compatible. Many additives

used with them are not compatible.

Solvents. Avoid.

solvents. Avoid.

aromatic hydrocarbons which should be avoided.

Compatible Lubricants

The following table lists known compatible lubricants and the manufacturer’s names. If you want to use a lubricant that is not listed below, contact the appropriate manufacturer for compatibility.

Figure 5-3. Compatible Lubricants

Lubricants Manufacturer

DC® 230 Molykote® 33

Harmony® 68 Security® 68

Lubriplate® Aero

Dow Corning Midland, MI 48640 (800) 248-2345

Gulf Oil Petroleum Prod. Dept. Pittsburgh, PA 15230 (412) 655-6247

Fisher Bros. Refinery 129 Lockwood Street Newark, NJ 07105

3500 Series Flat Panel Industrial PC

Lubricants Manufacturer

Martemp® 2500 E.F. Houghton & Co.

Nyogel® 795A Rheolube® 368 Rheolube® 723G Rheolube® 788 Synthetic Oil® 181 SF® 1147 Versilube® F-50

Terrestic ® 77 Exxon

Compatible Cleaning Agents

The following table lists known compatible cleaning agents. If you want to use a cleaning agent that is not listed below, contact the appropriate manufacturer for compatibility.

303 W. Lehigh Ave. Philadelphia, PA 19133 (215) 666-4000

Wm. J Nye P.O. Box G-927 New Bedford, MA 02742 (617) 966-6721

GE Silicone Products Waterford, NY 12188 (518) 237-3330

P.O. Box 2180 Houston, TX 77092 (713) 680-5712

Figure 5-4. 3515 Compatible Cleaning Agents

Type Agents

Aliphatics Hexane, Heptane, White Kerosene Mineral Spirits,

Alcohols Methyl, Isopropyl and Isobutyl, 1 + 3 Denatured

Halogenated Hydrocarbons Freons TF & TE Detergents and Cleaners Mild Soap and Water Solution, VM&P Naphtha

The above aliphatics, alcohols, and halogenated hydrocarbons should be used only for wiping or short-term immersion (less than 10 minutes). If parts are immersed completely, care should be taken to remove last traces of solvent by forced-air drying or rinsing in hot water.

Noncompatible Cleaning Agents

The following cleaning agents are known to be detrimental to the unit.

Figure 5-5. 3515 Non-compatible Cleaning Agents

Petroleum Ethers (65º C boiling point).

Alcohol.

Fantastik®, Windex®, Joy®, Top Job®, Mr. Clean®, Formula 409®.

Type Agents

Bases 25% Ammonium Hydroxide, 10% Potassium

Organic Solvents Lacquer Thinner, Toluene, Methyl Cellosolve,

Hydroxide, Sodium Hydroxide

Spare Parts List

Chapter Five - Maintenance

Methylethylketone

Figure 5-6. Spare Parts List

Description Xycom Automation Part Number

3515 Front Panel Assembly

With touchscreen

Without touchsc reen 3512KPM Touchscreen Replacement 3515KPM Touchscreen Replacment Drives

Hard Drive

6480 MB

Solid State (Flash) Drive

16 MB 24 MB 48 MB

3.5”, 1.44 Mbyte floppy drive

CD-ROM Drive Bulb Replacement Kits

12.1" TFT (#LQ12S 4 1 )

15” TFT (#LQ15XO1W)

15” TFT (#LQ150X1DG16) CPU Assembly

AHIP370 CPU board

300 MHz Celeron® processor

AHIP6+ CPU board

400 MHz Pentium II processor 450 MHz Pentium II processor 500 MHz Pentium III processor

CPU mounting kit SDRAM

32 MB 64 MB 128 MB 256 MB

9000-RFC 19” Floppy Door Plate Filter Media Media Retainer Input Power Connector

9000 Accessories

External Floppy Kit

9000-EXF 9000-FKA 9000-FFK

Consult factory for repair of 3512KPM front panels.

Includes touchscreen, front panel, c ont roller, and manual

Includes front panel and overlay only

ncludes touchscreen, controller, and m anual

AHIP6+ board and processor must be ordered separately.

The CPU mounting kit is only required for Pentium III processors.

Do not order these accessories if the 3515 ships with an internal floppy.

132566-001 132579-001 135162-001 139963-001

109456-005 139556-001

139557-001 139558-001 139964-001 139806-001

125155-001 132581-001 139965-001

139966-001 139785-001 139797-001 139786-001

139787-001 139967-001 139968-001

139798-001 139788-001 139799-001 139801-001

110843-001 110383 110650 139807-001

116074-001 116087-001 116061-001

3500 Series Flat Panel Industrial PC

roduct Repair Program/Returning a Unit to Xycom Automation

Xycom Automation’s Product Repair & Custom ization Departm ent (PR& C) restores equipment to normal operating condition and im plem ents engineering changes that enhance operating specifications. Xycom Automation tests products returned to Xy com with the standard Xycom Automation test diagnostics.

Follow the steps below to prepare the unit for shipment:

1. Obtain an RMA number for your unit by calling Xycom Autom ation headquarters, Prod-

uct Repair Department at 1-800-289- 9266 or 734- 429- 4971. Have the following inform ation ready:

• Company name, shipping and billing address.

• Type of service desired product repair or product exchange.

• Product model number, part number, quantity, serial number(s) (used to deter-

mine warranty).

• Failure mode and failure systems.

• Purchase order number or repair order number. No product out of warranty

will be returned without a purchase order number.

2. Make sure the front panel assembly is properly attached to the unit.

3. Attach failure information to the unit to speed processing.

4. Place the unit securely in its original packaging or an equivalent heavy-duty box.

5. Mark the RMA number on your purchase order and on the outside of the box.

6. Send the unit to your local Xycom Automation repair center.

Appendix A – Technical Specifications

Hardware Specifications

Figure A- 1. Hardware Specifications

Characteristic Specification

Mechanical

Height Width Depth (Mounting Depth) Weight

Electrical

Power Supply 200 watts Available Power

Passive Backplane Six full length expansion slots:

Mounting Panel Mount or 19" rack mount Flat Panels 12.1" TFT SVGA color display (800 x 600) (3512KPM)

Agency Approvals UL 1950 and 1604

Regulatory Compliance CE: EMI EN55022: 1994 Cl ass A

Total expansion power not to exceed 100 watts

Combined 3.3V and 5V is 10.6A

AC 115-230 VAC 50-60 Hz 6.3A autosensing

14.2" 19"

9.75" (9.00”) 42 lbs

+3.3 VDC 10.6A +5 VDC 10.6A +12 VDC 4. 88A

-12 VDC 0. 76A

-5 VDC 0. 50A

Five ISA slots One PCI bus expansion slot or four ISA Two PCI bus expansion slot (maximum 4.8” length with AHIP6+)

Note: Only five slots are avail abl e i f the optional Ethernet card is ins talled.

15” TFT XGA color display (1024 x 768) (3515, 3515KPM)

CUL C22.2, No. 950 and 213

IMMUNITY EN50082-2:1995 SAFETY E N60950

FCC 47 CFR. Part 15, Class A

b b

Environmental Specifications

Characteristic Specification

Temperature

Operating Nonoperating

Humidity

Operating Nonoperating

Figure A- 2. Environmental Specifications

0° to 50° C (32° to 122° F)

-20° to 60°C (-4° to 140°F)

20% to 80% RH noncondensing 20% to 80% RH noncondensing

3500 Series Flat Panel Industrial PC

Altitude

Operating Nonoperating

Vibration*

Operating

Nonoperating

Shock

Operating

These values are with solid state hard dri ves and not rotating media drives.

Nonoperating

CD-ROM and standard hard disk drives should not be used in applications where high levels of shock and vibration are present.

Sea level to 10,000 feet (3048 m) Sea level to 40,000 feet (12192 m)

5-55 Hz

0.006” peak to peak displacement 56-2000 Hz

1.0g maximum acc el eration 5-55 Hz

0.006” peak-to-peak displacement 56-2000 Hz

2.5 g maximum acc el eration

15g peak acceleration, 11 m sec duration 30g peak acceleration, 11 m sec duration

Note

If a CD-ROM drive is installed, the shock and vibration specifications of the unit are limited to the shock and vibration specifications of the CDROM drive.

Appendix B – Block Diagrams

TOUCHSCREEN

Appendix B – Block Diagrams

DC/AC

INVERTER

LAMP1

LAMP2

INTERNAL FLOPPY DRIVE OPTION

EXTERNAL FLOPPY CONNECTOR OPTION

T/S CONT. BOARD

TCTRL1

LED BOARD

DCINV1

TCTRL1

PARCOM2

RS-232

PARALLEL

COM1_4

RS232

RS485

KBMS1

AUX

KEYBD

LED

VGA1

FDD2

EXT.

VGA

FLOPPY

6-SLOT BACKPLANE

TCH1

DRAM SOCKETS

AHIPST ONLY

CPU BOARD

BACKPLANE CONNS. (2 PCI)

ATIDE1 PCIMG1

FDD1

LEDMSC1

ISA ISA ISA ISA

ISA or

PCI PCI

HARD DRIVE

DC INPUT

PWR1 PWR2

IDE1

HDD XXX HDD

HDD

INTERFACE

FPNL1

BOARD

TFT

CN1ACN2A

DC OUT

POWER SUPPLY

AC PLUG

BULB

SHARP 15“ TFT

LCD FLAT PANEL

BULB

FAN

AC IN

CD-ROM (OPTION)

XXX

Figure B- 1. 3515 TFT System Block Diagram

3500 Series Flat Panel Industrial PC

TOUCHSCREEN

DC/AC

INVERTER

LAMP1

LAMP2

INTERNAL FLOPPY DRIVE OPTION

EXTERNAL FLOPPY CONNECTOR OPTION

T/S CONT. BOARD

TCTRL1

LED BOARD

DCINV1

TCTRL1

PARCOM2

RS-232

PARALLEL

COM1_4

RS232

RS485

KBMS1

KEYBD

LED

VGA1

FDD2

EXT.

VGA

FLOPPY

6-SLOT BACKPLANE

TCH1

DRAM SOCKETS

CPU BOARD

BACKPLANE CONNS. (2 PCI)

ATIDE1 PCIMG1

AUX

FDD1

LEDMSC1

ISA ISA ISA ISA

ISA or

PCI PCI

HARD DRIVE

DC INPUT

PWR1 PWR2

IDE1

HDD

HDD XXX HDD

TFT

INTERFACE

FPNL1

BOARD

CN1A

POWER SUPPLY

AC PLUG

SHARP 15“ TFT

LCD FLAT PANEL

DC OUT

AC IN

BULB

FAN

CD-ROM (OPTION)

XXX

Figure B- 2. 3512KPM Block Diagram

Appendix C – Pinouts

This appendix provides the pinouts for the keyboard, AUX, LPT1, COM1, COM2, USB1, and VGA connectors. The following table defines abbreviations used in this Appendix.

Abbreviation Definition

NC No connect

Keyboard Port Connectors

This connector is a standard PS/2-compatible connector.

Pin Signal

1A KB_DATA 2A NC 3A GND 4A 5VFUSE 5A KB_CLK 6A NC

Appendix C–Pinouts

Aux Port Connector

This PS/2 mini-DIN connector allows you to attach a serial device.

Pin Signal

1B AUX_DATA 2B NC 3B GND 4B 5VFUSE 5B AUX_CLK 6B NC

You cannot use the AUX port when the touchscreen controller is using it.

Dual USB Connector (USB1)

Pin Number Description Pin Number Description

1A 5VFUSE 1B 5VFUSE 2A USBP0- 2B USBP13A USBP0+ 3B USBP1+ 4A GND 4B GND

Note

3500 Series Flat Panel Industrial PC

Parallel Port Connector (LPT1)

This is a 25-pin DB connector.

Pin Signal Pin Signal

1A STROBE 14A AUTOFEED 2A PD(0) 15A PERROR 3A PD(1) 16A INIT 4A PD(2) 17A SELIN 5A PD(3) 18A GND 6A PD(4) 19A GND 7A PD(5) 20A GND 8A PD(6) 21A GND 9A PD(7) 22A GND 10A PACK 23A GND 11A PBUSY 24A GND 12A PE 25A GND 13A SELECT

Serial Port Connectors

Serial ports RS-232 and RS-485 are supported on the AHIP6+ boards. Only one connector can be used at a time. All termination is done outside the unit.

COM1

RS-232 RS-485

Pin Signal Pin Signal

1A DCD1 1B TXD2A RXD1 2B TXD+ 3A TXD1 3B TXD TERM 4A DTR1 4B TXD TERM + 5A GND 5B GND 6A DSR1 6B RXD7A RTS1 7B RXD+ 8A CTS1 8B RXD TERM + 9A RI1 9B RXD TERM -

COM2

Appendix C–Pinouts

Technical Note

For TXD termination, connect a 150Ω, ½ watt resistor from pin 3B to pin 4B, with pin 1B connected to pin 3B and pin 2B connected to pin 4B. For RXD termination, connect a 150Ω, ½ watt resistor from pin 8B to pin 9B, with pin 6B connected to pin 9B and pin 7B connected to pin 8B.

RS-232

Pin Signal Pin Signal

1B ORB_GND 14B NC 2B TXD2 15B NC 3B RXD2 16B NC 4B RTS2 17B NC 5B CTS2 18B NC 6B DSR2 19B NC 7B GND 20B DTR2 8B DCD2 21B NC 9B NC 22B RI2 10B NC 23B NC 11B PB_RESET 24B NC 12B NC 25B NC 13B NC

The COM2 port can be used (only one at a time) for the touchscreen controller, IrDA interface, or RS-232 connector. The BI OS setup determ ines whether COM2 is used for either the connector or the IrDA interface. Jumpers on the touchscreen controller select the COM2 port or the AUX port.

VGA Connector

The VGA connector is a 15-pin connector.

Caution

Pin Signal

1RED 2 GREEN 3BLUE 4NC 5 ORB_GND 6 ORB_GND 7 ORB_GND 8 ORB_GND

3500 Series Flat Panel Industrial PC

Pin Signal

9 Fused VCC 10 ORB_GND 11 NC 12 DDCDAT 13 HSYNC 14 VSYNC 15 DDCCLK

External Floppy Connector

This connector is only available if the unit is ordered without the internal floppy (since the floppy interface supports only one floppy option).

Pin Signal Pin Signal

1 +5V 14 FSTEP 2 IDX 15 NC 3FDS1 16FWD 4 +5V 17 GND 5NC 18FWE 6 DCHG 19 GND 7NC 20FTK0 8NC 21GND 9GND 22FWP 10 MO1 23 GND 11 NC 24 FRDD 12 FDIRC 2 5 GND 13 NC 26 FHS

Appendix D – Replacing Flat-Panel Display Bulbs

We recommend sending the flat-panel display to Xycom Automation for bulb replacement. However, if you would like to replace the bulbs on site, this appendix provides instructions.

Note

Refer to the label on the back of your unit to determine the flat-panel display model. If you are unsure which instructions to use, call Xycom Automation Customer Support at 800-289-9266.

3515 TFT Flat-Panel Display (Sharp #LQ150X1DG16 or Samsung #LTM150XS-T01)

1. Turn off the power source.

2. Using a small Phillips-head screwdriver, loosen the two protruding captive screws

at the top back of the unit, and remove the lid.

FLAT PANEL DISPLAY SCREW (4)

(Remove for access to bulbs)

BULB CONNECTOR

FLAT PANEL DISPLAY

INVERTER CARD

CARRIER

BULB CONNECTOR

3. If a touch screen or keypad is installed, disconnect the cable(s) at the top of the

system board.

Figure D- 1. Model #LQ150X1DG16 - Front View

3500 Series Flat Panel Industrial PC

4. Set the unit with the front panel down and loosen the four captive screws holding

the front panel to the display adapter plate.

5. While securely holding the front panel, flip the unit over.

6. Lift off the front panel, and set it aside.

7. Unscrew the four screws that attach the flat panel display to the standoffs.

8. Disconnect the bulb connector from the inverter card.

9. Gently lift the left side of the flat panel display, and unscrew the two screws to

disconnect the data interface connector.

10. Turn the display face up on a protective surface.

11. Referring to Figure D-2, remove the two set screws and slide the bulb assemblies

out.

BULB CONNE CT OR

BULB AS S EMB L Y (P artially pulled ou t )

FLAT PANEL DIS P LAY

BULB CONNE CT OR

BULB ASSEMBLY SCRE WS (2)

(R emove to fr e e bul b ass embly from di s play)

Figure D- 2. Model #LQ150X1DG16- Rear View

Appendix D – Replacing Flat-Panel Display Bulbs

Note

Xycom Automation recommends replacing both bulbs at the same time.

12. Slide the new assemblies into the openings from which the old assemblies were

removed.

13. Repeat steps 1 through 9 in reverse order to reassemble the unit.

3515KPM, KPT, KPMT TFT Flat-Panel (Sharp #LQ150X1DG16 or Samsung #LTM150XS-T01)

1. Turn off the power source.

2. Unlatch and remove the lid.

3. If a touch screen is installed, disconnect the touch screen cable.

4. Disconnect the KEYPAD1, LEDKB1, and MS2 connectors.

5. Remove the four screws holding the front panel to the display adapter plate.

6. Remove the front panel, and set it aside.

7. Set the unit on the left side (power panel face down).

8. Disconnect the bulb connectors from the inverter.

9. Unscrew the four screws that attach the flat-panel display to the standoffs.

10. Disconnect the data interface cable from the display.

11. Gently lay the flat-panel display facedown on a protective surface next to the unit.

12. Referring to Figure D-3, unscrew the setscrews that secure the bulb assemblies

and slide the bulb assemblies out of the display.

BULB CONNECTOR

FLAT PANEL DISPLA Y

BULB CONNECTOR

BULB ASSEMBLY SCREWS (2) (Remove to free bulb assembly from display)

BULB ASSEMBL Y (Partially pulled out)

Figure D- 3. Model #LQ150X1DG16

3500 Series Flat Panel Industrial PC

13. Insert the new bulb assembly, and fasten the screw to secure.

Note

Xycom Automation recommends replacing both bulbs at the same time.

14. Reverse steps 1 through 10 to reassemble the unit.

3512KPM, KPT, KPMT TFT Flat-Panel Display (Sharp #LQ12S41)

1. Turn off the power source.

2. Unlatch and remove the lid.

3. If a touch screen is installed, disconnect the touch screen cable (TCH1).

4. Disconnect the KEYPAD1, LEDKB1, and MS2 connectors.

5. Set the unit with the front panel facing down, and remove the four screws holding

the front panel to the display adapter plate.

6. Flip the unit over, lift off the front panel, and set it aside.

7. Unscrew the four screws that attach the adapter plate to the standoffs.

8. Unscrew the four screws that attach the flat-panel display to the inner set of

standoffs.

9. Disconnect the bulb connectors from the inverter.

10. Gently lift the right side of the flat-panel display, and disconnect the data interface

connector (on the left side).

11. Lay the flat-panel display facedown on a protective surface.

12. Referring to Figure D-4, push in the tab at the end of the display with a flat-bladed

screwdriver, and slide the bulb assembly out.

BULB ASSEMBL Y

RELEASE CLIP

(PARTIALLY RETRACTED)

Appendix D – Replacing Flat-Panel Display Bulbs

BULB ASSEMBL Y

DISPLAY

ASSEMBLY

Figure D-4. Model #LQ12S41

13. Insert the new bulb assembly, and push in until the tab locks in place.

Note

Xycom Automation recommends replacing both bulbs at the same time.

14. Repeat steps 11 and 12 for the second bulb assembly.

15. Reverse steps 1 through 10 to reassemble the unit

INDEX

3500.........................................................5, 23, 24, 29, 57

3512KPM5, 6, 7, 14, 15, 16, 17, 21, 25, 26, 35, 42, 45,

47, 50, 54, 56, 61, 63, 66, 74

35155, 7, 12, 13, 16, 21, 25, 35, 40, 41, 42, 45, 47, 57,

60, 61, 62, 63, 65, 71

3515 Front Panel ..................................................... 12, 61

3515KPM 2, 5, 6, 7, 14, 15, 17, 25, 26, 54, 56, 61, 63, 73 Additional SDRAM Dual In-Line Memory Modules

(DIMMs)................................................................... 20

Alcohols.........................................................................60

Alpha Keys....................................................................51

AUX Port....................................................................... 17

Aux Port Connector.......................................................67

BIOS setup menus........................................................... 9

Block Diagrams.............................................................65

Bottom Panel................................................................. 18

bulb replacement............................................................71

Bulbs..............................................................................71

Cable Connections......................................................... 47

Cable Retainer Bracket ............................................ 41, 42

calibrating the touch screen ...........................................34

CD Drive .......................................................................17

CD-ROM Drivers.......................................................... 30

Chemical Compatibility.................................................59

Class I Locations ...........................................................45

Class II Locations..........................................................45

Close..............................................................................51

COM Ports..................................................................... 16

COM1..........................................................11, 16, 67, 68

COM2......................11, 13, 15, 16, 17, 31, 33, 34, 67, 69

Combo Keypad .............................................................. 53

Compatible Cleaning Agents......................................... 60

Compatible Lubricants...................................................59

Connectors......................................................... 24, 67, 68

Creating a Power Cable............................................. 8, 40

Cutout Dimensions............................................ 22, 24, 43

Definitions...............................................................36, 45

Delete.............................................................................51

diagnostic testing.............................................................9

diagnostics disk..............................................................11

Display...................................................12, 13, 15, 71, 74

Division 1 Locations......................................................45

Division 2 Locations......................................................46

Documentation kit..................................................... 7, 31

DOS.........6, 7, 8, 9, 11, 17, 28, 29, 30, 31, 33, 35, 36, 49

Download Menu............................................................ 53

Dual USB Connector (USB1)........................................67

Edit ....................................................................51, 52, 53

Electrical Noise..............................................................39

electromagnetic interference (EMI)...............................37

Enclosures......................................................................37

Environmental Specifications........................................63

Ethernet drivers..............................................................29

Ethernet Drivers.............................................................29

Ethernet Port.................................................................. 17

Excessive Heat............................................................... 39

Exhaust Fan................................................................... 20

Index

Exit ..................................................49, 50, 51, 52, 53, 54

Expansion Slots............................................................. 17

External Floppy Connector............................................70

External Hardware Options ........................................... 21

F/A Key................................................................... 15, 54

Factory Default.............................................................. 54

Fan and Filter.................................................................20

Fan Filter Replacement.................................................. 58

Files Menu.....................................................................51

Floppy Drive..........................................11, 17, 21, 22, 23

Front Access Keyboard and Floppy Connectors............ 23

Front Panel .............................................................. 12, 14

Func Lock OFF..............................................................54

Func Lock ON............................................................... 54

Function and User-Defined Keys...................................15

Function Keys................................................................51

Fuse Replacement..........................................................58

Groups..................................................................... 44, 46

Hardware Specifications................................................63

Hazardous Locations Installations................................. 43

I/O Panel........................................................................ 16

Installation...............................................................12, 20

Installing Drivers...........................................................29

Internal Hardware Options.............................................20

IR (Infrared)...................................................................13

Keyboard Port....................................................15, 16, 67

Keypad Inserts.........................................................15, 26

Keypad Scan Codes.......................................................54

Keypad Utility Program.................................................49

Keypad Version.............................................................53

Line Voltage Variation.................................................. 39

Loading the Keypad Utility........................................... 49

Logo...............................................................................25

Macros Edit Menu......................................................... 52

Macros Keypad Type Menu...........................................51

Main Menu................................11, 49, 50, 51, 52, 53, 54

Maintenance ..................................................................57

Miscellaneous Drivers...................................................31

Monitor Auxiliary Power Outlet....................................20

Mounting Considerations ..............................................36

Mounting the Unit.........................................................42

Mouse................................................................ 15, 31, 56

NEMA 4........................................5, 6, 12, 14, 31, 37, 42

Noncompatible Cleaning Agents ...................................60

Numeric/Cursor Control Keypad...................................15

Open ........................................................................51, 56

Operating Systems ......................................................... 28

Operation and Maintenance........................................... 47

Optional Features.............................................................6

Parallel Port............................................................. 16, 68

PC/AT................................................ 9, 10, 16, 20, 21, 49

PCI Boards .................................................................... 20

PF10 Key.......................................................................15

Pinouts...........................................................................67

Power Panel...................................................................19

Power Receptacle...........................................................20

Power Switch................................................................. 46

3500 Series Flat Panel Industrial PC

Preparing for the Tests.....................................................9

Product Repair & Customization Department........... 9, 62

PS/2 mini-DIN connector..............................................67

Quick Start-up..................................................................7

Retainer Bracket (AC) or P-Clamp (DC)....................... 20

RS-232........................................................... 5, 16, 68, 69

RS-485................................................................. 5, 16, 68

Running the Tests..........................................................11

Safety Agency Approval................................................48

Save.....................................................................7, 11, 51

SDRAM...............................................................5, 20, 61

Serial AUX.................................................................... 25

Spare Parts List........................................................ 57, 61

Specifying the Port........................................................ 34

Standard Features ............................................................5

Startup ........................................................................... 50

System Components ......................................................12

System Power................................................................ 38

System Status LEDs.................................................13, 15

Teach .......................................................................51, 5 2

Technical Specifications................................................63

Testing.............................................................................9

testing, diagnostic............................................................9

TFT flat panel......................................................7, 13, 15

touch screen

calibrating..................................................................34

touchscreen5, 7, 13, 15, 17, 18, 25, 30, 31, 33, 34, 61, 62,

67, 69

Touchscreen.......................................6, 30, 31, 33, 34, 61

Touchscreen Drivers......................................................30

Unpacking the System..................................................... 7

Upload Menu.................................................................53

USB Port........................................................................16

Using the Keypad Utility...............................................49

Utilities Menu................................................................54

Utility Batch Mode........................................................50

Vent Filter......................................................................20

VGA Connector............................................................. 69

Video Drivers ................................................................30

Video Expansion .....................................................35, 36

Video Port......................................................................17

View ......................................................41, 51, 52, 71, 72

Windows 3.1.................................................................. 29

Windows 95................................... 7, 8, 28, 29, 30, 35, 49

Windows keys................................................................ 15

Windows NT............................7, 8, 15, 28, 29, 31, 35, 49

Xycom 3500, 3515, 3515KPM, 3512KPM, 3515T Series Manual

Specifications and Main Features

Frequently Asked Questions

User Manual