Xycom 3510T, 3510KP, 3512KP, 3510KPT, 3512KPT User Manual

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3500 3-Slot Manual

3510T/3510KP(T), 3512T/3512KP(T), 3535T/3535KPM(T) Flat-Panel Industrial PCs

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

Revision Record

Revision Description Date

A Manual Released 5/99 B Updated Specifications 7/99 C Updated Bulb Replacement/CD-ROM Floppy addition 5/01 D Addition of 3535 Flat Panel Monitor PC 3/02 E Touchscreen Updates 7/02

Part Number 350003(E)

Trademark Information

Brand or product names are registered trademarks of their respective owners. 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.

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 designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial 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 interference 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 applying to the legal operation of this device. It is the responsibility of the system integrator and/or user to apply the following directions relating to installation and configuration:

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.

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 user’s authority to operate the equipment.

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

Table of Contents

CHAPTER 1 - INTRODUCTION..............................................................................................................................9

RODUCT OVERVIEW..................................................................................................................................................9

Standard Features.................................................................................................................................................9

Optional Features (All Units)..............................................................................................................................11

NPACKING THE SYSTEM .........................................................................................................................................11

UICK START-UP......................................................................................................................................................12

CHAPTER 2 - TESTING..........................................................................................................................................13

REPARING FOR THE TESTS ......................................................................................................................................13

UNNING THE TESTS ................................................................................................................................................15

CHAPTER 3 – INSTALLATION............................................................................................................................17

RONT PANEL...........................................................................................................................................................17

3510T/12T Front Panel.......................................................................................................................................17

3510KP/3512KP and 3510KPT/3512KPT Front Panel......................................................................................19

3535T Front Panel ..............................................................................................................................................21

3535KPM(T) Front Panel....................................................................................................................................22

I/O Panel 3510/1512 ...........................................................................................................................................23

I/O Panel 3535 ....................................................................................................................................................23

Back Panel...........................................................................................................................................................25

Power Panel ........................................................................................................................................................27

Preparing the System...........................................................................................................................................27

NSTALLING INTERNAL HARDWARE OPTIONS ...........................................................................................................28

DRAM and Additional DRAM Single In-line Memory Modules (SIMMs)...........................................................28

PC/AT and PCI Boards.......................................................................................................................................28

NSTALLING EXTERNAL HARDWARE OPTIONS ..........................................................................................................29

9000-EXF External Floppy Drive .......................................................................................................................29

9000-FFK External Front Floppy and Keyboard Access Kit..............................................................................29

9000-CDK External Front Access CD-ROM and Keyboard Kit.........................................................................31

USTOM LOGO .........................................................................................................................................................34

REATING CUSTOM KEYPAD INSERTS (FOR 3510/3512KP UNITS)...........................................................................35

EINSTALLING OPERATING SYSTEMS .......................................................................................................................39



MS-DOS Windows Windows Windows NT Windows

NSTALLING DRIVERS ...............................................................................................................................................41

reinstallation.....................................................................................................................................39



95 reinstallation................................................................................................................................40



98 reinstallation................................................................................................................................40



reinstallation...............................................................................................................................40



2000 reinstallation............................................................................................................................41

Ethernet Drivers..................................................................................................................................................41

Video Expansion..................................................................................................................................................42

Touchscreen Drivers............................................................................................................................................44

Miscellaneous Drivers.........................................................................................................................................44

SING A TOUCHSCREEN ........................................................................................................................................... 45

Calibrating the Touchscreen ...............................................................................................................................47

NSTALLING THE SYSTEM INTO A PANEL ...................................................................................................................48

Mounting Considerations....................................................................................................................................48

YSTEM POWER........................................................................................................................................................49

XCESSIVE HEAT......................................................................................................................................................49

LECTRICAL NOISE...................................................................................................................................................49

INE VOLTAGE VARIATION.......................................................................................................................................51

REATING A POWER CABLE......................................................................................................................................51

AC Power Cable..................................................................................................................................................51

DC Power Cable..................................................................................................................................................52

3500 Flat Panel Industrial PCs

OUNTING THE UNIT ...............................................................................................................................................53

System Cutout Dimensions .................................................................................................................................. 54

OWER SUPPLY ............................................................................................................................... .........................56

AZARDOUS LOCATIONS INSTALLATIONS ................................................................................................................ 57

AFETY AGENCY APPROVAL ....................................................................................................................................57

Definitions ...........................................................................................................................................................59

Class I Locations.................................................................................................................................................59

Class II Locations................................................................................................................................................59

Division 1 Locations............................................................................................................................................59

Division 2 Locations............................................................................................................................................60

Hazardous Locations Group Ratings..................................................................................................................60

NCLOSURES ............................................................................................................................................................60

OWER SWITCH ........................................................................................................................................................61

ABLE CONNECTIONS...............................................................................................................................................61

Communication Cable Interface..........................................................................................................................61

PERATION AND MAINTENANCE ..............................................................................................................................62

CHAPTER 4 - KEYPAD UTILITY FOR 3510KP/3512KPM...............................................................................63

OADING THE KEYPAD UTILITY................................................................................................................................63

SING THE KEYPAD UTILITY....................................................................................................................................63

CHAPTER 5 - KEYPAD UTILITY FOR THE 3535 KPM...................................................................................7 3

CHAPTER 6 - MAINTENANCE.............................................................................................................................81

REVENTIVE MAINTENANCE ....................................................................................................................................81

AINTENANCE .........................................................................................................................................................82

Fuse Replacement................................................................................................................................................82

Fan Filter Replacement.......................................................................................................................................82

HEMICAL COMPATIBILITY.......................................................................................................................................83

Compatible Lubricants........................................................................................................................................84

Compatible Cleaning Agents...............................................................................................................................85

Non-compatible Cleaning Agents........................................................................................................................86

3510/3512/3510KP/3512KP/3535KPM/3535T S P

RODUCT REPAIR PROGRAM/RETURNING A UNIT TO XYCOM AUTOMATION............................................................87

PARE PARTS LIST ........................................................................86

APPENDIX A – TECHNICAL SPECIFICATIONS..............................................................................................89

ARDWARE SPECIFICATIONS ....................................................................................................................................89

APPENDIX B - BLOCK DIAGRAM .....................................................................................................................91

APPENDIX C - PINOUTS.......................................................................................................................................93

KEYBOARD PORT CONNECTORS...............................................................................................................................93

UX PORT CONNECTOR............................................................................................................................................93

UAL USB CONNECTOR (USB1).............................................................................................................................94

ARALLEL PORT CONNECTOR (LPT1)......................................................................................................................94

ERIAL PORT CONNECTORS......................................................................................................................................94

COM1......................................................................................................................................................................95

COM2......................................................................................................................................................................95

VGA C E

ONNECTOR....................................................................................................................................................96

XTERNAL FLOPPY CONNECTOR ..............................................................................................................................96

APPENDIX D – REPLACING FLAT PANEL DISPLAY BULBS.......................................................................97

3510 U

NITS ..............................................................................................................................................................97

Mitsubishi TFT Flat panel Display (model #AA104VB02)..................................................................................97

3512

AND 3512 KP UNITS........................................................................................................................................99

Table of Contents

Mitsubishi TFT Flat panel Display (Model #AA121SK12) .................................................................................99

NDEX.....................................................................................................................................................................103

Chapter 1 - Introduction

Product Overview

The 3500 series Flat-Panel Industrial Computers combine an Intel Celeron or Pentium III processor with a flat-panel display to offer a powerful, compact package for the factory floor and other harsh environments. The PC features an open architecture to meet a wide variety of applications that require both a powerful PC and a durable industrial enclosure.

The 3500 systems include:

• A three-slot ISA/PCI backplane which accommodates ¾ length expansion cards

• Flat panel displays

• 3510 – 10.4” – 640x480 VGA (TFT)

• 3512 – 12.1” – 800x600 SVGA (TFT)

Chapter One - Introduction

• 3535 – 15” – 1024x768 XGA (TFT)

• Touchscreen versions 3510T/3512T/3535T

• Keypad version (3510KP/3512KP/3535KPM)

• Keypad and touchscreen units (3510KPT/3512KPT/3535KPMT)

• Hard disk drive facilities

The front panel of the unit is sealed to NEMA 4/4X/12 and IP65 standards, and is protected by an impact-resistant shield.

The system’s modular design allows easy access to expansion boards, switches, power supply, flat-panel display, and disk drives.

Standard Features

The 3500 3-slot series ships standard with the following:

• Intel Celeron or Pentium III processor

• Up to 512 MB DRAM

• 10 GB hard drive

• 2 Serial ports

• 1 RS-232 or RS-485 port

• 1 Dedicated RS-232

• Reprogrammable keypad or analog resistive touchscreen, or both for operator input

• Two USB ports

3500 Flat Panel Industrial PCs

• IP65 standard

• UL listed for hazardous locations: Class I, Division 2

• Power supply

• MS-DOS operating system

• Flash BIOS

• 5.75” mounting depth (6.5” with external floppy option, 7.16” with external CD-

ROM/floppy drive option)

• External floppy connector

• Flat-panel display

• 10.4” TFT (640x480) (3510)

• 12.1” TFT (800x600) (3512)

• Three AT bus ¾ length expansion slots

• One ISA slots

• One PCI slot

• One ISA/PCI slot

• IR Port (IrDA, HPSIR, AND ASKIR compatible)

• Rear PS/2 keyboard port and mouse port (also front PS/2 keyboard port on 3510KP

and 3512KP)

• Keypads (3510KP/3512KP)

• 32 relegendable function keys (64 with the F/A function)

• Keypad (3535KPM)

• 74-position keypad and industrial mouse (touchscreen option)

• 40 relegendable keys (80 with F/A key)

• Status LEDs

• Power

• Disk

• Com

• Input

• External floppy and CD-ROM option, side access

• MS-DOS

Windows 95, Windows 98, Windows NT or Windows 2000

• Front panel sealed to meet NEMA 4/4X/12 and IP65 specifications when panel

mounted

• Status LEDs

• Power

• Disk

• Com

• Input

Optional Features (All Units)

Following are optional available features:

• Faster processor speeds

• Touchscreen-resistive technology with less than 1.5% linearity error

• Preinstalled Windows 95, Windows 98, Windows 2000 or Windows NT

• 9000-EXF, hot installable external floppy drive

• 9000-RF1 19-inch Rack Mount Adapter Plate (3510, 3512)

• 9000-FFK, NEMA 4 Front Floppy Kit

Chapter One - Introduction

• 9000-RFC 19-inch Floppy Door Plate

• 2005-RMA 19 inch Rack Mount Adapter Plate (3510KP, 3512KP)

• 9000-CDK, NEMA 4 front Access CD-ROM and keyboard kit

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.

• 3510T/3512T/3535T or Keypad version

• Documentation kit, which includes:

• Power connector

• Diagnostic software diskette

• 14 10-32 hex nuts (2 spares)

• Clip-on Ferrite for mouse cables

• Cable clamp and screw (for strain relief of power cord)

• 3510/3512/3535 manual

• CPU manual (CD-ROM)

• Utility diskettes

If you ordered the system with a touchscreen installed, you will also receive a touchscreen driver diskette and a documentation CD that includes the manual.

3500 Flat Panel Industrial PCs

Quick Start-up

This section gives you the steps to get the system up and running without explaining the capabilities and options.

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

To prepare the system for use, perform the following steps.

1. Attach 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 24 VDC outlet, whichever applies. (See Chapter 3, Creating a Power Cable.)

4. Turn on the power to the unit. The system will boot up into the operating system.

Warning

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

Chapter 2 - Testing

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

Remove device drivers and memory resident programs (TSRs) that are installed on the system before running Xycom diagnostics. If this step is not completed unexpected failures may occur.

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

• Press

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

• Press ESC

• Press ENTER twice to save the settings and exit.

Refer to the CPU manual for more information on the Setup Menu.

F2 after the POST RAM test has completed.

Chapter Two - Testing

Note

Preparing for the Tests

To test your system, you need the following equipment:

• Floppy disk drive

• IBM PC/AT or PS/2-compatible

• Xycom System Test Disk 3.5 inch, DS/DD disk (bootable), Xycom part number

99290-001

• Centronics-compatible printer cable

• Parallel printer (Centronics-style interface)

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

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

3500 Flat Panel Industrial PCs

Perform the following steps before starting the system tests:

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

the 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, Serial Loopback Connections, 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

Note

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

Note

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.

Chapter 3 – Installation

This chapter illustrates the installation of, and the options for, the 3500. The figures on the next several pages show the internal and external components on the front and back panels of the unit to help you locate features relevant to installation.

Front Panel

The 3500 series has a NEMA 4/4X/12 and IP65 sealed front panel. The panel protects the system’s interior when the system is properly panel mounted.

3510T/12T Front Panel

Chapter Three - Installation

Figure 3-1. 3510T/3512T Front Panel

3500 Flat Panel Industrial PCs

Feature Description

Display The 3510 has a 10.4-inch TFT Active Matrix Color LCD flat panel. Impact-

resistant shield protects the display from breakage. The 3512 has a 12.1” TFT Active Matrix Color LCD flat panel. An impact-resistant shield protects the display from breakage. If a touchscreen is factory installed, it is backed by heat-annealed safety glass replacing the impact-resistant shield.

Diagnostic LEDs Following is a description of the LEDs and what it means when they're lit:

Power Lit when the system has power Disk Lit when the computer is accessing the disk drive COM Lit when there is communication activity on one of the serial

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

Input Lit when the unit has a touchscreen (LED gets brighter when a

touch input is detected) or a key is pressed

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 located behind this window. The IR port is IrDA

and ASKIR compliant. Connect the unit to any IrDA compatible device. Load special software (not included) to use this feature. The infrared (IR) link is designed to operate at a distance of 0 to 1 meter. Enable the interface through the BIOS setup menu. Note: When the IR port is

chosen in the system BIOS, COM2 is not available.

Keyboard Port Access (Optional front access)

The 3510/3512 supports one PS/2 keyboard. Front access options are available with the use of the 9000-FKA Front floppy/keyboard access kit (not shown). The access is a PS/2 stacked mini-din located on the side of the unit. Warning: To maintain safe conditions, do not use an external

keyboard and/or mouse port when the unit is operating in a hazardous environment.

Floppy Disk Drive (Optional) The 3510/3512 has front access options available. (Refer to the External

Floppy Option section within this chapter.)

Chapter Three - Installation

3510KP/3512KP and 3510KPT/3512KPT Front Panel

The 3510KP and 3512KP have NEMA/4/4X/12 sealed front panels. The panel protects the system’s interior when the system is properly panel mounted. Figure 3-2 illustrates the front panel with keypad.

Figure 3-2. 3510KP/12KP Front Panel

Feature Description

Display The 3510KP/3512KP has a 10.4-inch (640 x 420) TFT flat panel

display or a 12.1-inch SVGA (800 x 600) TFT flat panel display.

Diagnostic LEDs The 3510KP/3512KP features status LEDs on the front panel,

which allows monitoring of the system operation. Following is a description of the LEDs and what it means when they're lit:

Power Lit when the system has power Disk Lit when the computer is accessing the disk drive COM Lit when there is communication activity on one of

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

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 Indicates the keypads are in alpha mode

Function and User-Defined Keys These 32 relegendable function keys (64 using the F/A keys)

provide easy access to familiar routines. (F/A keys 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 Control Keypad Use the data entry keypad to enter data and move the cursor.

3500 Flat Panel Industrial PCs

Feature Description

PF10 Key (Keypad Configuration Key) This key reconfigures your keypad. Keyboard Port (3510KP/3512KP)

(front access)

The 3510KP/3512KP provides both front and rear accessible PS/2 keyboard connectors. The front accessible connector is located on the lower right side of the front panel. The rear accessible connector is located on the side of the unit.

Note: Only one keyboard port on the 3510/3512KP can be used at a time.

Note: The installation of the touchscreen driver determines whether a second pointing device will function correctly. If using a mouse with a touchscreen, please review the Touchscreen Driver Installation instructions.

3535T Front Panel

TOUCH

SCREEN

(OPT IONAL )

IR PORT

Chapter Three - Installation

POWER DISK COM INPUT

IR PORT POWER DISK

COM

INPUT

Feature Description

Display The 3535T has a 15-inch (1024 x 768) XGA flat panel display. Diagnostics LED The 3535T features four status LEDs on the front panel, which

you can use to monitor system operation. Power There is power to the 3535. 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

3535 IR port is IrDA, and ASK-IR compliant. You can connec t the 3535 to any IrDA compatible device, if you load special software (not included). The infr ar ed (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 menus.

Note: When the IR port is chosen, COM2 is not available. Correspondingly, if COM2 is in use by the touchscreen the IR is not operational.

3500 Flat Panel Industrial PCs

3535KPM(T) Front Panel

Flat Panel Display

Programmable Fun cti on K eys

Configuration Key

Keyboar d Input

Funct ion Keys

IR DA PORT

Industrial Mouse

Programmable Funct i on Keys

F/A Key

Windows Keys

Numeric Keypad

Cursor Control System

Status LED (Power)

System Statu s LE D (Input)

COM DISK

Feature Description

Display The 3535KPM(T) TFT flat panel impact-resistant shield protects the display from

breakage. If a touchscreen is factory installed, the touchscreen is backed by heatannealed safety glass replacing the impact-resistant shield.

System Status LEDs The 3535 features four status LEDs on the front panel, which you can use to

monitor system operation. Power There is power to the 3535. 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 3535 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 operates at a distance of 0 to 1 m eter and is c apable of 115 Kbaud trans f er rates. Enable the interface through the BIOS setup menus.

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

Note: When the IR

I/O Panel 3510/1512

(3)

)

EXPANSION SLOTS (3)

LID

ETHERNET

PORT

LID

REMOVAL

SCREW (2)

MOUNTING

STUD (12)

COM 2 RS-232

COM 1 RS-485

Chapter Three - Installation

MOUSE

VIDEO

FRONT PANEL

I/O Panel 3535

EXPANSION SLOTS

LID

ETHERNET

PORT

LID

REMOVAL

SCREW (2)

MOUNTING

STUD (12)

PARALLEL RS-232

KEYBD

Figure 3-3. System I/O 3510/1512Panel

COM 2 RS-232

COM 1 RS-485

MOUSE

USB PORT (2 )

VIDEO

FRONT PANEL

PARALLEL

RS-232

KEYBD

Figure 3-4 System 3535 I/O Panel

USB PORT (2

3500 Flat Panel Industrial PCs

Feature Description

Parallel Port The parallel printer port (LPT1) is a 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 that controls this option.

COM Ports COM1 is RS-232/485 compatible. RS/232 is connected to the lower nine-pin stacked

DB connector. The top part of this stack is the RS/485 version of the same port. Since these connectors are attached to the same port, only one can be used at a time. COM2 is the male 25-pin DB connector. COM2 is dedicated to the IR port, the touchscreen controller, or the 25-pin connector. Only one option can be used at a time.



Note: If you ordered Windows NT

, the driver is on disk and a copy of the driver file is on the hard drive. This operating system only supports COM2. Therefore, the touchscreen will be on COM2, and COM2 will not be available for other use.

Keyboard Port The keyboard port is a PS/2 stacked mini-din so a PC/AT keyboard can be attached at

either the front or side of the unit. The keyboard port on the side of the unit is the lower connector. Do not use when in the presence of a hazardous environment. Note: You

cannot use both keyboard ports on the 3535 at the same time.

Mouse Port The mouse port is a PS/2 stacked mini-din that allows you to attach a mouse at the

side of the unit. If you receive a unit with a touchscreen, this port may be covered with a label stating that the port is not functional as shipped. This is dependent upon the operating system installed.



Note: If the unit has a touchscreen and MS-DOS, Windows

3.x or Windows 95, the touchscreen is configured for the mouse port, making the mouse port unavailable. Reconfigure the touchscreen for use on COM2 to make mouse port functional.

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

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 shipped disabled. 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 flat panel. To use both a video display on the video port and the flat panel display, you must enable “Simultaneous Video” on the Advanced Menu in the BIOS setup. Refer to the CPU manual for details.

USB Universal Serial Bus (not available with AHIP4+ CPU)

Ethernet Port

This port provides a 10BASE-T/100BASE-TX autosensing Ethernet connection.

(optional)

Back Panel

Chapter Three - Installation

Figure 3-4. System Back Panel with Optional Removable Floppy Drive

OPTIONAL

FLOPPY

DRIVE

MOUNTING

STUD (12)

FRONT PANEL

BACK PANEL

SCREWS

FRONT PANEL

TTAC HMENT SCREWS

LID SCREWS LID

FAN FILTER

BACK PANEL

LID REMOVAL

Figure 3-5. System Back Panel with Optional Pre-installed Non-removable Floppy Drive

3500 Flat Panel Industrial PCs

CD-ROM/Floppy Drive Covers

Mounting Screw

Figure 3-6. System Back Panel with Optional Pre-installed Non-removable CD-ROM/Floppy Drive

CD-ROM/Floppy Drive Mounting Screws ( 4)

Back Panel

Feature Description

Fasteners There are two protruding screws (lid removal screws) along the

top of the back panel. Loosen these screws to remove the lid. There are four screws located across the top and bottom of the back panel. Loosen these screws (using a Phillip-head screwdriver) to remove the front panel.

Note: If your system has a touchscreen, disconnect the touchscreen cable from the CPU board before removing the back of the system from the front bezel.

Optional External Removable Floppy Disk Drive

Optional Non-removable Floppy Disk Drive

Optional Non-removable CDROM/Floppy Drive

You can install the optional 9000-EXF external floppy disk drive to the back of the 3500.

You can order the 3500 with an optional non-removable floppy disk drive on the back of the 3500.

You can order the 3500 with an optional CD-ROM/Floppy disk drive mounted on the rear of the system.

Chapter Three - Installation

Power Panel

Figure 3-7. Bottom Panel with Power Connector and External Floppy Connector

Feature Description

Power Connector This is a three-pin connector. Refer to the special hazardous

location installation instructions later in this chapter. External Floppy Drive Connector This is a 26-pin connector. Product ID Label The product ID label is located on the bottom panel Fan and Filter The filter can be replaced or removed for cleaning. See Chapter 5

for details on the fan filter assembly.

Preparing the System

Read this chapter first, comply with all the safety requirements, and then mount the unit according to the following instructions.

1. Locate a position that meets the required specifications.

2. Create a panel cutout. The dimensions are given in this chapter.

3. Install optional equipment following the instructions in Installing Internal

Hardware Options and Installing External Hardware Options in this chapter.

4. Create a power cable. Refer to the Creating a Power Cable section in this

chapter.

5. Mount the system and properly secure the unit into the panel. See Installing the

System section in this chapter.

6. Attach one end of the power cord to the power receptacle and the other end to a

properly grounded 115/230 VAC, 50-60 Hz outlet or a 24 VDC outlet, whichever applies (refer to the Hazardous Location Installations section later in this chapter).

7. Turn on power to the system. The system will boot up to the operating system

installed.

8. Install the application software via a floppy drive.

3500 Flat Panel Industrial PCs

If a touchscreen is factory installed, along with MS-DOS, the mouse port is unavailable. The unit will arrive with a sticker placed over the port. If you would like to reconfigure the touchscreen to use the COM2 port, follow the instructions in the Using a Touchscreen section in this chapter.

Installing Internal Hardware Options

Caution

Turn off the unit before installing internal hardware.

Warning

Installation of expansion boards may void safety and/or EMC compliance.

Remove the lid to install internal hardware options.

DRAM and Additional DRAM Single In-line Memory Modules (SIMMs)

You can order the 3500 system CPU factory-configured for many configurations of DRAM. You can reconfigure the DRAM capacity by changing the DRAM SIMMs on your board. For more information refer to the CPU manual.

PC/AT and PCI Boards

1. Check that the memory and I/O configuration of the board you want to install

does not conflict with the CPU and I/O memory maps in your CPU board manual.

2. Remove the lid.

3. Remove the ORB screw in the desired track.

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

5. Push the board into the backplane connectors.

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.

Note

7. Replace the lid.

Installing External Hardware Options

This section explains how to install the external hardware options available with the system.

Note

When using the external floppy drive, do NOT attach the drive with a diskette installed. You may corrupt the disk.

9000-EXF External Floppy Drive

The external floppy (9000-EXF) can be mounted on the back of the unit. There are four screw holes on the back of the unit for the floppy mounting. A fifth screw hole is on the back for the cable clamp screw. See the Figures 3.4 and 3.7 of the back panel and the bottom panel.

Front mounting options are also available.

Chapter Three - Installation

Note

Make sure the floppy drive cable will reach the external floppy connector on the system before making the cutout.

9000-FFK External Front Floppy and Keyboard Access Kit

If you want to relocate the floppy drive to the front of the computer module, you must install the 9000-FFK (Front Floppy Keyboard Access Kit), which includes a front access keyboard port. The floppy drive access door is provided for installations using the 9000-RFC Rack Filler Plate with Cutout, or panel mount installations that provide a cutout for the front mounted floppy drive.

3500 Flat Panel Industrial PCs

Mount the floppy drive access door to the rack 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 NM).

Figure 3-8. Front Mounted Floppy Cutout Dimensions

The following figure shows an overhead view of the Front Floppy Kit (9000FFK) with the floppy drive mounted.

Figure 3-9. 9000FFK - Front Mounting Option

Chapter Three - Installation

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

9000-CDK External Front Access CD-ROM and Keyboard Kit

The 9000-CDK is a front access CD-ROM. This option (purchased separately) connects to the parallel and keyboard ports on the 3500. The 9000-CDK assembly functions as a parallel port CD-ROM while providing an additional parallel port for printer use. The 9000-CDK includes a separate power supply that must be connected for the CD-ROM to work. The supplied driver also needs to be installed on the 3500 unit for the CD-ROM to function. The 9000-EXF can be mounted in the 9000-CDK (purchased separately) if front access floppy is desired. Refer to Figure 3-13 for cutout dimensions.

3500 Flat Panel Industrial PCs

.26 (6.604)

4.20 (106.68)

DOOR KNOB

6.83 (173.482)

.180 DIA - .000 THRU (6 PLACES)

CUTOUT

3.675 (93.345) (2 PLACES)

7.350 (186.69) (2 PLACES)

Figure 3-13. 9000-CDK - Cutout

4.800 (121.92) (3 PLACES)

INCHES (mm)

9000-EXF

5.6 (142.24)

CD-ROM DRIVE FRONT PANEL

Figure 3-14. 9000-CDK – Front Mounting Option (side view)

INCHES (mm)

3 (76.2)

2 (50.8)

9000-EXF FLOPPY DRIVE MOUNT

10.2 (259.08)

FLOPPY DRIVE MOUNTING SCREWS (4)

PANEL MOUNTING STUD (6)

Chapter Three - Installation

DOOR KNOB

8.15 (207.01)

CD-ROM FRONT PANEL

INCHES (mm)

Figure 3-15. 9000-CDK Front Mounting Option – Top View

3500 Flat Panel Industrial PCs

Custom Logo

You have the option to place a custom label on the unit. Refer to Figure 3-13 for the dimensions and recommended requirements for a customized label. Once a customized label is procured, place the new label over the “Xycom Automation” label (inside the recessed area).

0.55 (13.97)

0.06 (1.52) (4 Places)

Your Logo On Entire Surfac

2.05 (52.07)

NOTE: All dimensions are in inches (mm) RECOMMENDED MATERIA L : 0.007 (0.176) thick polyester with 3M #468 adhesive on far side

Figure 3-16. Logo Label Dimensions

Chapter Three - Installation

Creating Custom Keypad Inserts (for 3510/3512KP Units)

You can customize your keypad with keypad inserts. Refer to Figures 3-14, 3-15, and 3-16 for insert dimensions and installation.

Figure 3-17. 3510KP/3512KP Keypad Inserts with Dimensions (PF1 – PF12)

Figure 3-18. 3510KP/3512KP Insert with Dimensions (F1 - F20)

3500 Flat Panel Industrial PCs

Figure 3-19. 3510KP/3512KP Keypad Insert Position

Creating Custom Keypad Inserts (3535)

You can customize your keypad with keypad inserts. Refer to Figure 3-15 and Figure 3-16 for insert dimensions and installation.

Chapter Three - Installation

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

3500 Flat Panel Industrial PCs

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

Figure 3-15 provides information on positioning keypad inserts.

Chapter Three - Installation

Figure 3-17. Keypad Insert Position

Reinstalling Operating Systems

The 3500 CPU ships with MS-DOS pre-installed. Optionally available, are Microsoft Windows 95, Windows 98, Windows NT, and Windows 2000 operating systems. If you want to install a different operating system, refer to that operating system’s manual for directions.

MS-DOS reinstallation

If you need to reinstall MS-DOS, refer to the Xycom Automation Workstation Recovery Media Software Installation Instructions for Microsoft

(shipped with systems pre-installed with MS-DOS). This document is devoted to the reinstallation of your MS-DOS operating system and drivers utilizing the Recovery Media provided with your Xycom Automation industrial computer.

NOTE: This procedure assumes that the computer hard disk drive has been completely corrupted or replaced.

WARNING: This procedure will destroy data that may exist on the hard disk drive.



DOS 6.22

3500 Flat Panel Industrial PCs

Windows 95 reinstallation

If you need to reinstall the Windows 95 operating system, refer to the Xycom Automation Workstation Recovery Media Software Installation Instructions for



Microsoft

This document is devoted to the reinstallation of your Microsoft Windows 95 operating system and drivers utilizing the Recovery Media provided with your Xycom Automation industrial computer.

NOTE: This procedure assumes that the computer hard disk drive has been completely corrupted or replaced.

WARNING: This procedure will destroy data that may exist on the hard disk drive.

Windows 95 (shipped with systems preinstalled with Windows 95).

Windows 98 reinstallation

If you need to reinstall Windows 98 refer to the Xycom Automation Workstaion Recovery Media Software Installation Instructions for Microsoft

(shipped with systems preinstalled with Windows 98). This document is devoted to the reinstallation of your Windows Workstation operating system and drivers utilizing the Recovery Media provided with your Xycom Automation industrial computer.



Windows 98

NOTE: This procedure assumes that the computer hard disk drive has been completely corrupted or replaced.

WARNING: This procedure will destroy data that may exist on the hard disk drive.

Windows NT reinstallation

If you need to reinstall Windows NT refer to the Recovery for Xycom Automation



Windows NT

This document is devoted to the reinstallation of your Windows NT Workstation

4.0 operating system and drivers utilizing the Recovery Media provided with your Xycom Automation industrial computer.

NOTE: This procedure assumes that the computer hard disk drive has been completely corrupted or replaced.

WARNING: This procedure will destroy data that may exist on the hard disk drive.

Note: If you need to reinstall the Windows NT or Windows 95 operating system, you

must have an internal CD-ROM drive or an external parallel port CD-ROM drive. Windows NT ships only on a CD-ROM disk.

Workstation (shipped with systems preinstalled with Windows NT).

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.

Windows 2000 reinstallation

If you need to reinstall Windows 2000 refer to the Xycom Automation Workstation Recovery Media Software Installation Instructions for Microsoft

(shipped with systems preinstalled with Windows2000). This document is devoted to the reinstallation of your Windows2000 Workstation operating system and drivers utilizing the Recovery Media provided with your Xycom Automation industrial computer.

NOTE: This procedure assumes that the computer hard disk drive has been completely corrupted or replaced.

WARNING: This procedure will destroy data that may exist on the hard disk drive.

Installing Drivers

This section describes how to install the drivers associated with the system.

Chapter Three - Installation



Windows 2000

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 the AHIP4+ board is installed, your system must have BIOS revision level 1.7 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,

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.

Note

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 Xycom 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.

3500 Flat Panel Industrial PCs

Video Drivers Video drivers and the expansion utilities are on the diskette included with the

documentation kit as well as on the hard drive. For the AHIP6+ system, the video drivers are in the following directories: C:\VGA\C&T554\WIN95

C:\VGA\C&T554\WINNT C:\VGA\C&T\DOS\UTILITIES

For the AHIP4+ system, the video drivers are in the following directories: C:\VGA\C&T550\WIN95

C:\VGA\C&T550\WINNT C:\VGA\C&T\DOS\UTILITIES

Video Expansion

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

Note

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

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. In order to more efficiently make use of the flat panel display’s active area, it is necessary to employ an expansion technique which 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 800 x 600 display of the system 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 95, and Windows NT use display drivers to handle the different flat panel displays. Here expansion is not necessary since there is a specific driver for each resolution display.

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 from the process of expansion. If the effect of expansion is undesirable, it can be turned off either in the BIOS setup, 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.

Video Expansion Options

Chapter Three - Installation

Utility Mode Panel Type/Size

12.1” TFT

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

Definitions:

Vert - Vertical only expansion is invoked Vert/Hor - Vertical and Horizont al expansion is invoked Expansion Default - The video BIOS default on power up

* Text expansion cannot be turned off With an 800 x 600 display, the stretching algorithm does not completely fill the

display horizontally or vertically. A greater vertical text expansion can be achieved by changing to VGA mode 3* (see Note below). This is also an 80 column, 25 row text mode but with an effective resolution of 640 x 350. The 350 lines stretch better to fill the 768-line display than does the default DOS mode 3+.

Note

The utility diskette includes a program titled MOD3_350.EXE, to allow switching to the VGA mode 3*. Another utility program, MOD3_400.EXE, is provided to put the mode back to the DOS default of 3+.

Windows may come up with a blank screen when using Windows 3.X with expansion turned on either through the BIOS setup or the EXP_ON.EXE utility. The two options (second option being the best) for this situation are listed below:

• Option 1 – Pressing the

display, letting you know that pressing

CTRL-ALT-DEL keys simultaneously. A blue screen will

CTRL-ALT-DEL again will reboot the

system or pressing any key will return you to Windows. At this point, press any key and the normal Windows screen should appear.

• Option 2 – Turn off the expansion, set the BIOS default in the BIOS setup menus

using the appropriate utility as shown in the Video Expansion Options table.

Note

For further assistance, call Xycom Automation technical support at 1-800-289-9266.

3500 Flat Panel Industrial PCs

Touchscreen Drivers

If you have a touchscreen factory installed, you will also receive at no charge: MSDOS, and Windows 95 touchscreen drivers on diskette. Touchscreen drivers for Windows NT (9460-DRVNT) and OS/2 (9460-DRVOS/2) must be purchased separately.

The Windows 95 touchscreen driver is available in a COM2 and a mouse port version. Windows NT touchscreen driver is only available in a version for COM2

If you order Windows NT pre-loaded on a system, the Windows NT touchscreen drivers are provided.

You must install the corresponding touchscreen driver software if you change the operating system. Refer to the touchscreen manual for instructions.

Note

If you ordered Windows 95 and a touchscreen on your system, the touchscreen driver has been installed. If you ordered Windows NT, the driver is on diskette and a copy of the driver file is on the hard drive. Windows NT only supports COM2. Therefore, the touchscreen will be on the COM2 port and COM2 will not be available for other use.

Miscellaneous Drivers

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

If you had Windows NT preloaded on your system, you may have to purchase and install an external parallel port CD-ROM drive, or order your system with CD-ROM drive to install Windows NT drivers. The Windows NT operating system only ships on CD-ROM.

Note

Using a Touchscreen

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. The touchscreen Monitor Mouse driver emulates a Microsoft mouse.

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 MS-DOS, or Windows 95 is installed on your system, the touchscreen is configured for the mouse port and the mouse port is unavailable.

Chapter Three - Installation

Note

If Windows NT is installed on your system, the touchscreen is set up on COM2 and the COM2 port is unavailable for other use.

To reconfigure the touchscreen to use the COM2 port, perform the following steps:

1. Disconnect the power.

2. Remove the lid.

Figure 3-17A. Touchscreen Controller Card

3. Remove the touchscreen controller card (Figure 3-

3500 Flat Panel Industrial PCs

Xycom Controller

To reconfigure the touchscreen to use the COM2 port, perform the following steps:

17A).

4. Reconfigure Jumpers J1-J5. Position A = COM2.

Position B = PS/2 mouse.

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 COM2.

• Recalibrate the touchscreen.

8. Replace the lid.

1. Disconnect the power.

2. Remove the lid.

J1 J2 J3 J4

JUMPERS

J7 J8 J9

TOUCH SCREEN

NTROL CONN.

Figure 3-17B. Touchscreen Controller Card

3. Remove the touchscreen controller card (Figure 3-

17B).

4. Reconfigure Jumpers J1-J9. Position A = COM2.

Position B = PS/2 mouse.

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 Xycom Documentation CD

• Follow the instructions in the readme.txt file for

the installation of the UPDD driver in serial mode.

8. Replace the lid.

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

Chapter Three - Installation

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

3500 Flat Panel Industrial PCs

Installing the System into a Panel

The system’s rugged design allows it to be installed in most industrial environments. The system is generally placed in a NEMA 4/4X/12 enclosure to protect against contaminants such as dust, moisture, etc. Metal enclosures also help minimize the effects of electromagnetic radiation that nearby equipment can generate.

Mounting Considerations

Once you have established a location for the 3500, install it in the enclosure according to the instructions that follow:

• Select a NEMA rated enclosure and place the unit to allow easy access to the system

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 that has 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, make

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

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

interference (EMI) or radio frequency 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

transformers, local power disconnects, and surge suppressers) away from the system. The proper location of incoming line devices keep power wire runs as short as possible 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 rack or panel in such a way as to ensure that it does not cause a hazard

from uneven mechanical loading.

• Incorporate a readily accessible disconnect device in the fixed wiring on permanently

connected equipment.

• Avoid circuit overloading of the supply circuit.

System Power

Using isolation transformers on the incoming AC power line to the system is always a good practice. An isolation transformer is especially desirable in cases in which heavy equipment is likely to introduce noise onto the AC line. The isolation transformer can also serve as a step-down transformer to reduce the incoming line voltage to a desired level. The transformer should have a sufficient power rating (units of volt-amperes) to supply the load adequately.

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

Chapter Three - Installation

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

installations where high levels of electrical noise can be expected. The rack/chassis should be grounded with a ground rod or attached to 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 units withstand temperatures from 0º to 50ºC. The systems are cooled by convection, in which a vertical column of air is drawn in an upward direction over the surface of its components. To keep the temperature in range, the cooling air at the base of the system must not exceed 50°C. Allocate proper spacing between internal components installed in the enclosure.

When the air temperature is higher than the specified maximum in the enclosure, use a fan or air conditioner to lower the temperature.

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 only at certain times, may appear as 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 noise signal carrier lines.

3500 Flat Panel Industrial PCs

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, motors, and motor starters.

Refer to the relevant Federal, State/Provincial, and local electric codes which provides 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.

Line Voltage Variation

The unit’s power supply is built to operate with output voltage ranges of 90-132 VAC and 180-264 VAC or 20-36 VDC, whichever applies, 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 3510/3512 by compensating for voltage changes at the primary in order to maintain a steady voltage at the secondary. When using a constant voltage transformer, check that the power rating is sufficient to supply the unit.

Creating a Power Cable

Chapter Three - Installation

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

AC Power Cable

You must create an AC power cable to supply power to units with AC power supplies. You will need the following materials:

• 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 wire, rated 80º C or better.

Perform the following steps to create the cable:

1. Cut the 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.

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.

4. Insert the three wire ends of the power cable into the three holes of the block

plug. Insert the Protective Earth GND ground, L1, and L2/N wires into the corresponding holes, as shown in Figure 3-8. Be sure that no bare wires are exposed.

3500 Flat Panel Industrial PCs

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.

6. Use a cable clamp and #6-32 screw (provided) to secure and provide strain relief

to the power cable. When installing the power cable to the unit, use the securing screws on each side of the plug. This strain relief is mandatory for hazardous locations compliance.

Figure 3-21. AC Power Connector

Warning

Completely loosen the two securing screws on the plug when disconnecting the power cord from the unit.

DC Power Cable

You must create a DC power cable to supply power to units with DC power supplies. You will need the following materials:

• A three-position power connector (supplied)

• A braid/foil shielded power cable with three 18 (1.0 mm), 16 (1.3 mm), or 14 (1.6

mm) AWG solid or stranded copper wire, rated 80º C or better. Perform the following steps to create the DC power cable:

1. Cut the 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 stop fraying.

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.

Chapter Three - Installation

4. Insert the three wire ends of the power cable into the three holes of the block

plug. Insert the Protective Earth GND ground, + (positive), and - (return) wires into the corresponding holes, as shown in Figure 3.19. Be sure that no bare wires are exposed.

Figure 3-22. DC Power Connector

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.

6. Use a plastic cable clamp and #6-32 screw (provided) to secure and strain-relief

the cable. When installing the power cable to the unit, use the securing screws on each side of the plug.

Completely loosen the two securing screws on the plug when disconnecting the power cord from the unit

Installation is complete once the power and other optional interface cables are installed.

Mounting the Unit

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).

Warning

2. Cut the hole according to the cutout dimensions in Figure 3.20 or Figure 3.21.

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

4. Install the unit.

3500 Flat Panel Industrial PCs

61.6

5. Attach the power cable making sure that the system’s enclosure is grounded

through the power cable.

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

unit chassis to the enclosure chassis. A 6-32 threaded ground point hole is provided on the bottom panel of the unit.

7. Tighten the 12-#10 nuts to 25 lbs-inch (2.8 Newton-meters) (28Kgf cm).

System Cutout Dimensions

3510(T)/3512(T)

6.150 [156.21]

2.150 [54.61]

.315 [8.00]

12.300 [312.42]

10.150 [257.81]

10.300 [2

11.670 [2 96.42 ]

5.150 [1 3 0.81]

1.315 [33.40]

1.650 [41.91]

8.650 [219.71]

9.630 [244.60]

ø.250 [ø6.35]

Figure 3-23. 3510/3512 System Cutout Dimensions (inches [mm])

.350 [8.89]

Chapter Three - Installation

3510KP/3512KP, 3510KPT/3512KPT

15.800 [401.32]

14.150 [359.41]

7.900 [200.66]

1.650 [41.91 ]

5.775 [146.69]

[293.37]

10.400 [264.16]

11.55

3.85 7 [97.97] .457 [11.61]

8.085 [205.36]

12.085 [306.96]

13.170 [334.52]

.800 [20.32]

1.150 [29.21]

10.850 [ 275.59]

15.100 [383.54]

ø.250 [ø6.35]

Figure 3-24. 3510KP/3512KP System Cutout Dimensions (inches [mm])

3535KPM and 3535T

18.3 12 [4 65 .12]

14.457 [367.21]

9.157 [232.59]

17.400 [441.96]

5.085 [129.16]

.685 [ 1 7.40]

1.085 [27.56]

12.370 [314.20]

Figure 3-25. 3535KP System Cutout Dimensions (inches [mm])

ø.250 [ø6.35]

3500 Flat Panel Industrial PCs

Power Supply

The power supply provides 80 watts of output throughout the system’s temperature range. The expansion power is limited as shown in the following table.

Voltage Available Current

+5 VDC 6.17A +3.3 9A +12 VDC 1.88A +5 6A

-12 VDC 0.71A +12 1.5A

Total expansion power not to exceed 46 watts

Total expansion power not to exceed 48 watts

Available Expansion Current

AHIP4+ (5x86 processors) aAHIP-370

(Celeron and Pentium II/III processors)

-12 .45A

Hazardous Locations Installations

Xycom Automation designed the systems to meet the requirements of Class I, Division 2 Hazardous Locations applications. Division 2 locations are those locations that are normally non-hazardous, but could become hazardous due to accidents that may expose the area to flammable vapors, gases or combustible dusts.

These systems have been designed as non-incendiary devices. 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 systems 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 design intent. Xycom Automation accepts no responsibility for installations of this equipment or any devices attached to this equipment in Division 1 locations.

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

Note

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 locations installations should be inspected by the appropriate authority having jurisdiction prior to use. Only technically qualified personnel should install, service, and inspect these systems.

Safety A gency A pprov al

The Xycom Automation systems have the following approvals:

• Underwriters Laboratories Inc., UL 1604 Standard for Safety. Electrical equipment

for use in Class I and Class II, Division 2, and Class III hazardous (classified) locations.

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

recognized, File E181675)

• 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. (CUL recognized, File E181675).

• EN60950, Information Technology equipment

3500 Flat Panel Industrial PCs

•

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.

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

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

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

Warning

Warning - Explosion Hazard

Advertissment Risque D’ Explosion

Warning - Explosion Hazard

Advertissment Risque D’ Explosion

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

Advertissment Risque D’ Explosion

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

Warning - Explosion Hazard

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

Warning

In order to maintain a safe condition, do not use an external keyboard or mouse when the unit is operating in a hazardous environment.

Definitions

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 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.

3500 Flat Panel Industrial PCs

Division 2 Locations

Division 2 locations are listed below:

• 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

positive 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: 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.

Hazardous Locations Group Ratings

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 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.

Enclosures

The systems are designed for installation within a clean and dry enclosure for both ordinary and hazardous locations. The front panel meets the requirements of UL and CSA 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.

Note

Warning

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

Panel flatness and rigidity are important if a proper panel seal is to be maintained. If non-metal type enclosures, such as plastic or fiberglass, are to be used, 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.

Power Switch

The 3500 systems do not have a power switch. The amount of input power required by these systems classifies the power switch as an incendiary device because the voltage and current across the make/break device are capable of creating a spark.

Chapter Three - Installation

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.

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 location regulations require that all cable connections be provided with adequate strain relief and positive interlock. Never connect or disconnect a cable while power is applied at either end of the cable.

Communication Cable Interface

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 workstation mating connectors via the two screws located on both sides.

3500 Flat Panel Industrial PCs

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.

In order to maintain a safe condition, never use an external keyboard or mouse when the unit is operating in the presence of a hazardous environment.

Warning

With respect to Hazardous Location installations, always observe the following rules:

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

application. 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

accumulation of foreign matter inside the workstation.

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

known to be removed 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.

4. 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.

Chapter Four – Keypad Utility

Chapter 4 - Keypad Utility for 3510KP/3512KPM

A Keypad Utility lets the user redefine all keypad keys with new scan codes using utility software.

Note

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

Loading the Keypad Utility

Note

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

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

Using the Keypad Utility

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

You need a full-stroke keyboard to enter keystrokes while recording a new key macro, editing an existing macro, and entering utility commands. All keys on the keypads are redefinable. 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 can be used to exit from 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 chosen to exit this menu.

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

3500 Flat Panel Industrial PCs

Startup

Type KPUTIL to run the full Keypad utility.

Utility Batch Mode

A mode is also available for reprogramming keypads from a batch file. This feature is useful if you wish to reprogram many units with customized keypad macros without having to enter the full 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 utility and then used to reprogram other units from a batch file.

The command filename runs the utility batch mode. Filename is the file containing the new keypad macros. You must include the filename extension. For example, the batch file def3512.pkm will reprogram the keypad with def

ault values.

Main Menu

The Main Menu is shown illustrated. Each menu option is described in the next few paragraphs.

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.

Files Menu

Open

Chapter Four – Keypad Utility

Files containing keypad macro sets (a macro for each key) may be saved on disk and loaded 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 Files, a pull-down menu is displayed that provides the following choices: Open, Close, Save, Save As, Delete, and Exit.

Opens a file that contains a macro set for the keypad and loads the contents into memory. Any macro set in memory is overwritten. Once loaded, the macro set is available to edit, view, teach, and/or download to the keyboard controller.

Clears the macro set from memory and closes the file from which they came.

Save

Copies the macro set from memory back into its original file. The original file contents are overwritten.

Save As

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

Delete

Deletes a file.

Exit

Returns to the Main Menu.

Macros Keypad Type Menu

When you select Macros, a pull down menu displays and provides the following choices: Function Keys, Alpha Keys, and Exit. Once function or alpha is selected the menu displays the following choices once the Macros menu is chosen:

Exit, View, Teach, and Edit.

3500 Flat Panel Industrial PCs

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

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.

Macros Edit Menu

Note

Exit

View

Returns to the Main Menu.

Lets you 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 The ASCII line 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, as explained below. There is a one-to-one correspondence between the ASCII and code lines to help interpret the code line.

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. Default is Hex. 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.

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

Teach

Edit

Chapter Four – Keypad Utility

Allows you to record up to 105 keystrokes in a macro. When selected, a graphic representation 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 chooses 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

ENTER. After a key is selected, the utility records every key stroke on the

external 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 it is not a recordable key. However,

ESC stops recording and returns

ESC can be included in a

macro by using the editor. Changes made to the macros in the Teach Menu are not programmed until you select Download.

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 press

ENTER.

Cut

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 actual editing takes place. The bottom line (the ASCII line) displays the macro in ASCII format and is not user configurable. This line helps keep track of which part of the macro you are editing, and will be updated by the utility as editing takes place. For example,

edit line 1275F075

F0 12 1C F0 1C 12 22 F0 22 F0 12 0

ASCII line sh 8 bk 8

bk sh a bk a sh X bk X bk sh EOM

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.

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 Flat Panel Industrial PCs

4. 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

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.

Paste

Insert 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 press

Codes

Displays a table of keys and their scan codes in Hex. See the Codes section later in this chapter for a complete code listing.

Hex/Decimal

Toggles between displaying the scan codes in Hex and Decimal formats.

F1 and select Copy.

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

Edit line.

ENTER.

F1. Select Paste and then

ENTER.

Insert

Toggles between insert and overtype mode.

Upload Menu

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

Combo Keypad

Commands the keyboard controller to send its entire macro set for the keypad.

Version

Commands the keyboard controller to send its firmware revision number.

Exit

Returns to the Main Menu.

A checksum will be calculated during transmission and an error message displays if an error occurs.

Download Menu

Any macro set previously programmed is overwritten when you select Download.

Chapter Four – Keypad Utility

Note

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

Note

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, keyboard controller programs its EEPROM with the new macros which become the new key definitions for the keypad.

Utilities Menu

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

Func Lock ON

Not available on the 3510KP/3512KP.

Func Lock OFF

Not available on the 3510KP/3512KP.

Clear EEPROM

Erases the EEPROM memory. This clears the entire keypad macro set. After using this feature, the unit should be turned off and then on. This will initialize the EEPROM with the default settings.

3500 Flat Panel Industrial PCs

Exit

Returns to the Main Menu.

Codes

Special keyboard controller codes replace the standard IBM scan codes for 101-key keyboard enhanced keys in macros that use these keys. The special scan codes are listed in the table below:

Special Scan Codes

Code Meaning

E2 E3 E4 E5 E6 E7 E8 E9 EA EB EC ED EE

Insert Home Page Up Delete End Page Down Up Arrow Left Arrow Right Arrow Down Arrow Forward Slash Print Screens/Sys Rq Pause/Break

The following table lists the default keypad keycodes the utility produces.

Default Keypad Keycodes

Chapter Four – Keypad Utility

3512KP

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 F1 / G F1 05 F0 05 G 34 F0 34 F2 / H F2 06 F0 06 H 33 F0 33 F3 / I F3 04 F0 04 I 43 F0 43 F4 / J F4 0C F0 0C J 3B F0 3B F5 / K F5 03 F0 03 K 42 F0 42 F6 / L F6 0B F0 0B L 4B F0 4B F7 / M F7 83 F0 83 M 3A F0 3A F8 / N F8 0A F0 0A N 31 F0 31 F9 / O F9 01 F0 01 O 44 F0 44 F10 / P F10 09 F0 09 P 4D F0 4D F11 / Q F11 12 05 F0 05 F0 12 Q 15 F0 15 F12 / R F12 12 06 F0 06 F0 12 R 2D F0 2D F13 / S F13 12 04 F0 04 F0 12 S 1B F0 1B F14 / T F14 12 0C F0 0C F0 12 T 2C F0 2C F15 / U F15 12 03 F0 03 F0 12 U 3C F0 3C F16 / V F16 12 0B F0 0B F0 12 V 2A F0 2A F17 / W F17 12 83 F0 83 F0 12 W 1D F0 1D F18 / X F18 12 0A F0 0A F0 12 X 22 F0 22 F19 / Y F19 12 01 F0 01 F0 12 Y 35 F0 35 F20 / Z F20 12 09 F0 09 F0 12 Z 1A F0 1A PF7 / ( F31 11 05 F0 05 F0 11 ( 12 46 F0 12 F0 46 PF8 / ) F32 11 06 F0 06 F0 11 ) 12 45 F0 12 F0 45 PF9 / * F33 11 04 F0 04 F0 11 * 12 3E F0 12 F0 3E PF10 / \ F34 11 0C F0 0C F0 11 \ 5D F0 5D PF11 / / F35 11 03 F0 03 F0 11 / 4A F0 4A PF12 / : F36 11 0B F0 0B F0 11 : 12 4C F0 12 F0 4C CTRL CTRL 14 F0 14 CTRL 14 F0 14 SHIFT SHIFT 12 F0 12 SHIFT 12 F0 12 INS INS 70 F0 70 INS 70 F 0 70 ALT ALT 11 F0 11 ALT 11 F0 11 TAB TAB 0D F0 0D TAB 0D F0 0D DEL DEL 71 F0 71 DE L 71 F0 71 F/A SPACE SPACE 29 F0 29 SPACE 29 F0 29 + + 79 F0 79 + 79 F0 79 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 46 F0 46 6 46 F0 46 7 7 25 F0 25 7 25 F0 25 8 8 3E F0 3E 8 3E F0 3E

F/A key led OFF ( Function Mode ) F/A key led ON ( Alpha Mode ) Keyboard

Equivalent

Make Codes

Break Codes Keyboard

Equivalent

Make Codes

Break Codes

3500 Flat Panel Industrial PCs

3512KP

Description of key

9 9 46 F0 46 9 46 F0 46 . . 49 F0 49 . 49 F0 49 0 0 45 F0 45 0 45 F0 45

- - 7B F0 7B - 7B F0 7B BACKSPACE BACK SPACE 66 F0 66 BACK SPACE 66 F0 66 up arr up arr E0 12

PREV PgUp E0 12 E07DE0 F0 7D left arr left arr E0 12 E06BE0 F0 6B ][ HOME E0 12 E06CE0 F0 6C right arr ri ght arr E0 12 E074E0 F0 74 ESC ESC 76 F0 76 ESC 76 F0 76

down arr down arr E0 12 E072E0 F0 72 NEXT PgDn E0 12 E07AE0 F0 7A ENTER ENTER 5A F0 5A ENTER 5A F0 5A

F/A key led OFF ( Function Mode ) F/A key led ON ( Alpha Mode ) Keyboard

Equivalent

Make Codes

E0 75

Break Codes Keyboard

Equivalent

E0 F0 75 E0 F0 12

E0 F0 12 E0 F0 12 E0 F0 12 E0 F0 12

E0 F0 12 E0 F0 12

Contrast Up E0 12 PgUp E0 12 E07DE0 F0 7D Contrast Down E0 12 E06BE0 F0 6B HOME E0 12 E06CE0 F0 6C Contrast Up E0 12 E074E0 F0 74

Contrast Down E0 12 E072E0 F0 72 PgDn E0 12 E07AE0 F0 7A

Make Codes

E0 75

Break Codes

E0 F0 75 E0 F0 12

E0 F0 12 E0 F0 12 E0 F0 12 E0 F0 12

E0 F0 12 E0 F0 12

NOTE: F11-F20 = SHIFT F1-F10

F21-F26 = CTRL F1-F6 F31-F36 = ALT F1-F6

Note

If you make any changes to your keypad and want to set it back to the default settings, open the file titled DEF9462.PKM from the File/Open menu and then download it from the download menu. Do not save any changes to the default files.

Chapter Five – Keypad Utility for 3535

Chapter 5 - Keypad Utility for the 3535 KPM

The 3535KPM 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

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

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

chosen to exit this menu.

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

3500 Series Flat Panel Industrial PC

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.

Main Menu

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.

Files Menu

Chapter Five – Keypad Utility for 3535

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

contents 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.

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

came.

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

file contents are overwritten.

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

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

NOTE: The 3535KPM uses 3515KP files.

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

3500 Series Flat Panel Industrial PC

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 line 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

representation 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 external 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

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

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.

Chapter Five – Keypad Utility for 3535

Upload Menu

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.

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

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

Edit line.

3. Move the cursor on the last character to copy and press The copied item does not appear on the screen until you select

ENTER.

Paste.

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 and then press

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

F1. Select Paste

See the 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.

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

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.

3500 Series Flat Panel Industrial PC

Download Menu

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

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.

Note

Command Description

Func Lock ON Locked Func Lock OFF Unlocked Factory Default Reprograms the keypad macros to the factory default settings. After

completion, the system will reboot.

Exit Returns to the Main Menu.

Keypad Scan Codes

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

Default Keypad Keycodes

3535KPM 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 F 0 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

Keyboard Equivalent

Make Codes

Break Codes Keyboard

Equivalent

Make Codes

Break Codes

Chapter Five – Keypad Utility for 3535

3535KPM F/A Key LED Off (Function Mode) F/A Key LED On (Alpha Mode)

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 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 S HI F T 12 F0 12 ESC ESC 76 F0 76 ESC 76 F0 76 ALT ALT 11 F0 11 ALT 11 F0 11 TAB TAB 0D F0 0D TAB 0D F0 0D DEL DEL E0 12 E0 71 E0 F0 71 E0 F0 12 DE L 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

BACK SPACE

66 F0 66 BACK

SPACE

66 F0 66

3500 Series Flat Panel Industrial PC

3535KPM F/A Key LED Off (Function Mode) F/A Key LED On (Alpha Mode)

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 E0 12 E0 75 E0 F0 75 E0 F0 12 + + 79 F0 79 + 79 F0 79 left arr left arr E0 12 E0 6B E0 F0 6B E0 F0 12 left arr E0 12 E0 6B E0 F0 6B E 0 F0 12 HOME HOME E0 12 E0 6C E0 F0 6C E0 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 E0 12 E0 74 E0 F0 74 E0 F0 12 PgDn PgDn E0 12 E0 7A E0 F0 7A E0 F0 12 PgDn E0 12 E0 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

(windows start menu)

Explorer Mouse click

(windows pop-up menu)

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

NOTES:

• F11-F20 = SHIFT F1-F10

• PF1-PF10 = CTRL F1-F10

• PF11-PF20 = 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 from the File/Open menu and then download it from the download menu. Do not save any changes to the default files.

Chapter 6 - Maintenance

The 3500 is designed to withstand the harsh environment of the factory floor. Routine maintenance can help keep your system in good operating condition. Preventive maintenance consists of several basic procedures that will greatly reduce the chance of system malfunction. Schedule preventive maintenance along with the regular equipment maintenance to minimize down time.

Preventive Maintenance

Here are some preventive measures you can take:

• Clean the monitor screen using a non-residue cleaner such as a mild window

cleaning solution or CRT screen cleaner. Take care not to scratch 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.

Chapter Six - Maintenance

• Base your maintenance schedule on the type of environment the system is in (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

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

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

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

• 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 3510/3512.

• Stock spare parts to minimize down time resulting from part failure. Spare parts

stocked should be 10 percent of the number of each unit used. Main CPU cards should have one spare each. Each power supply should have a back up. In applications where immediate operation of a failed system is required, you may need to stock an entire spare computer module. Refer to the Spare Parts List in this chapter.

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

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

3500 Series Flat Panel Industrial PC

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. 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.

Maintenance

This section describes the maintenance you can perform on the 3500.

Fuse Replacement

The 3500 has no accessible fuse. Return the unit to for fuse replacement.

Fan Filter Replacement

To change the fan filter, remove the grill and filter as illustrated in Figure 5-1 or replace the filter and snap the assembly back into position.

Figure 5-1. Fan Assembly

Do not operate the 3500 without a fan filter. Dust build-up could cause the unit to malfunction.

Chemical Compatibility

Certain combinations of chemical environments, temperature, and stress can adversely affect parts made from thermoplastic resin. For this reason material which may come in contact with the 3500 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 following table lists general chemical compatibility guidelines.

Chapter Six - Maintenance

Caution

3500 Series Flat Panel Industrial PC

3510/3512 Chemical Compatibility

Chemical Class

Acids No effect under most common conditions of concentration and

Alcohols Generally compatible at low concentration and room temperature.

Alkalis Generally compatible at low concentration and room temperature.

Aliphatic Hydrocarbons

Amines Surface crystallization and chemical attack. Avoid. Aromatic

Hydrocarbons Detergents

and Cleaners Esters Causes severe crystallization. Partial solvents. Avoid. Greases and

Oils Halogenated

Hydrocarbons Ketones Causes severe crystallization and stress cracking. Partial solvents.

Silicone Oil and Greases

Effects

temperature.

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

Generally compatible

Partial solvents and severe stress cracking agents. Avoid.

Mild soap solutions are compatible. Strong alkaline materials should be avoided.

Pure petroleum types generally compatible. Many additives used with them are not compatible.

Solvents. Avoid.

Avoid. Generally compatible up to 85ºC (185º F). Some contain 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.

Lubricants Manufacturer

DC® 230 Molykote® 33

Harmony® 68 Security® 68

Lubriplate® Aero

3500 Compatible Lubricants

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

Martemp® 2500 E.F. Houghton & Co.

303 W. Lehigh Ave. Philadelphia, PA 19133

(215) 666-4000 Nyogel® 795A Rheolube® 368 Rheolube® 723G Rheolube® 788 Synthetic Oil® 181 SF® 1147 Versilube® F-50

Terrestic ® 77 Exxon

Wm. J Nye

P.O. Box G-927

New Bedford, MA 02742

(617) 966-6721

Silicone Products

Waterford, NY 12188

(518) 237-3330

P.O. Box 2180

Houston, TX 77092

(713) 680-5712

Chapter Six - Maintenance

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.

3510/3512/3510KP/3512KP Compatible Cleaning Agents

Type Agents

Aliphatics Hexane, Heptane, White Kerosene Mineral Spirits,

Petroleum Ethers (65º C boiling point).

Alcohols Methyl, Isopropyl and Isobutyl, 1 + 3 Denatured

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

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

Formula 409®.

The above aliphatic, alcohol, and halogenated hydrocarbon agents should be used only for wiping or short-term immersion (less than 10 minutes). If parts are in complete immersion, care should be taken to remove last traces of solvent by forcedair drying or rinsing in hot water.

3500 Series Flat Panel Industrial PC

Non-compatible Cleaning Agents

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

3500 Non-Compatible Cleaning Agents

Type Agents

Bases 25% Ammonium Hydroxide, 10% Potassium

Hydroxide, Sodium Hydroxide

Organic Solvents Lacquer Thinner, Toluene, Methyl Cellosolve,

Methylethylketone

3510/3512/3510KP/3512KP/3535KPM/3535T Spare Parts List

3510/3512/3510KP/3512KP Spare Parts List

DESCRIPTION PART NUMBER 3510 PART NUMBER 3512 PART NUMBER 3535

FRONT PANEL ASSEMBLY

Touch Screen

TFT

KPa (3510/3512) KPM (3535)

Non-touch

TFT

KP (3510/3512)

KPM (3535)

DRIVES

Hard Drive

CPU ASSEMBLY

Celeron 433 MHz

Pentium III 600 MHz

Pentium III 700 MHz

DRAM

16Mx32 (64 Mbytes)

32Mx32 (128 Mbytes)

117334-101 119045-101

132274-001 132290-001

132566-001

117334-001 119045-001

140334-001 142046

132579-001

109456-004 109456-004 109456-005

Call Xycom Call Xycom Call Xycom

132455-001 132455-001 13788-001

133813-001 133813-001 139799-001

RACK FILLER PLATE

9000-RFI 19” Rack Filler Plate

116771-001 116771-001 110843-001

Chapter Six - Maintenance

DESCRIPTION PART NUMBER 3510 PART NUMBER 3512 PART NUMBER 3535

FLOPPY DOOR PLATE

9000-RFC 19” Floppy Door Plate

FILTER MEDIA

110843-001 110843-001 110843-001

Filter Media

MEDIA RETAINER

Media Retainer

INPUT POWER CONNECTOR

Input Power Connector

9000 ACCESSORIES

9000-EXF External Floppy Kit

9000-FFK

9000-CDK

Panel assembly includes T/S controller

110383 110383 110383

110650 110650 110650

99711-001 99711-001 139807-001

116074-001 116074-001 116074-001

116061-001 Call Xycom 11606-001

Call Xycom

Product Repair Program/Returning a Unit to Xycom Automation

Xycom Automation’s Product Repair & Customization Department (PR&C) restores equipment to normal operating condition and implements engineering changes that enhance operating specifications. Xycom Automation tests products returned to Xycom with the standard Xycom test diagnostics.

Follow the steps below to prepare the unit for shipment:

1. Obtain an RMA number for your unit by calling your nearest Xycom

Automation Repair Department or Xycom Automation, Inc. at 1-800-289-9266 or 734-429-4971.

2. Please have the following information:

• Company name, shipping and billing address

• Type of service desired: product repair or product exchange

• Product model number, part number, quantity, serial number(s), and

warranty status

• Failure mode and failure systems

• Purchase order number or repair order number

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

3500 Series Flat Panel Industrial PC

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

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

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

7. Send the unit to the address given when you receive your RMA number.

Many technical support issues or problems can be resolved through our Web site at www.xycom.com. Some of the items that you can find there are:

• Distributor Locator and the Online Support Database

• In the Support Center you will find Hardware & Software Driver Downloads,

IPC Application Notes, and Knowledge Database.

• In the Product Center you will find Data Sheets and Manuals for download.

Appendix A – Technical Specifications

Hardware Specifications

Characteristic 3510/3512KP 3535KPM

Mechanical Height Width Depth

Weight

11.0” Front Panel, 12.25” (KP units)

13.0” Front Panel, 16.50” (KP units)

6.5” overall

5.65” behind front panel

1.00” front panel protrusion

7.4” overall with back-mounted external floppy

16 lbs, 18 lbs with external floppy

14.2” 19”

9.75” (9.00”)

42 lbs

Electrical AC DC Power Supply 80 Watts 80 Watts Passive Backplane One ISA slot

Available Power

Mounting Panel mount or 19” rack with optional filler

Flat Panel 10.4” TFT active color display

Agency Approvals UL 1950

Regulatory Compliance

115/230 VAC - 50-60 Hz - 3.0/1.5 A 20-36 VDC - 24 V nominal - 10 A max

One PCI slot One PCI or PCI bus ¾ length expansion

slot

With AHIP-370 CPU board +3.3 V, 9 A +5 V, 6A +12 V, 1.5A

-12 V, 0.71A CAUTION: Total expansion power not to

exceed 48 watts.

plate

12.1” TFT active color display

UL 1604 CUL C22.2, No. 950 CUL C22.2, No. 213 FCC: 47 CFR. Part 15, Class A CE:

115/230 VAC - 50-60 Hz - 3.0/1.5 A autosensing

One ISA slot One PCI slot One PCI or PCI bus ¾ length expansion

slot With AHIP-370 CPU board +3.3 V, 9 A +5 V, 6A +12 V, 1.5A

-12 V, 0.71A CAUTION: Total expansion power not to

exceed 48 watts. Panel mount or 19” rack mount

15” TFT XGA color display (1024 x768)

UL 1950 UL 1604 CUL C22.2, No. 950 CUL C22.2, No. 213 FCC 47 CFR. Part 15, Class A CE:

3500 Series Flat Panel Industrial PC

Characteristic 3510/3512KP 3535KPM

EMI EN55022 IMMUNITY EN50082-2: SAFETY EN60950

Temperature

Operating: 0° to 50° C (32° to 122° F) TFT Non-operating: -20° to 60° C (-4° to 140°

Humidity Operating: 20% to 80% RH

noncondensing Non-oprating: 20% to 80% RH

noncondensing

Altitude Operating: Sea level to 10,000 ft (3048m)

Non-operating: Sea level to 40,000 ft (12192 m)

Vibration

5 to 2000 Hz Operating: 0.006” (0.15mm) peak-to-peak

displacement 1.0 max accleration Non-operating: 0.015” (0.38mm) peak-to-

peak displacement 2.5 max. acceleration

Shock

Operating: 15g peak acceleration, 11 msec duration

Non-operating: 30g peak acceleration, 11 msec duration

EMI EN55022: 1994 Class A IMMUNITY EN50082-2:1995 SAFETY EN60950

Operating: 0° to 50° C (32° to 122° F) Non-operating: 20° to 60° C (-4° to 140°

F) Operating: 20% to 80% RH

noncondensing Non-oprating: 20% to 80% RH

noncondensing Operating: Sea level to 10,000 ft (3048m) Non-operating: Sea level to 40,000 ft

(12192 m) 5 to 2000 Hz Operating: 0.006” (0.15mm) peak-to-

peak displacement 1.0 max accleration Non-operating: 0.015” (0.38mm) peak-to-

peak displacement 2.5 max. acceleration Operating: 15g peak acceleration, 11

msec duration Non-operating: 30g peak acceleration, 11

msec duration

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

Total expansion power not to exceed 100 watts

Appendix B - Block Diagram

Appendix B – Block Diagram

Figure B- 1. 3500 3-slot System Block Diagram

Appendix C - Pinouts

This appendix provides the pinouts for the keyboard, AUX, LPT1, COM1, COM2, USB1, and VGA connectors. (NC indicates no connection.)

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.

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

Pin Signal

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

Note

3500 Series Flat Panel Industrial PC

Dual USB Connector (USB1)

This connector is only available on units with AHIP6+ boards.

Pin Number Description Pin Number Description

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

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 AHIP4+ and the AHIP6+ boards. Only one connector can be used at a time. All termination is done outside the unit.

COM1

Appendix C - Pinouts

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 -

Technical Note

COM2

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

3500 Series Flat Panel Industrial PC

The COM2 port can be used (only one at a time) for the touchscreen controller, IrDA interface, or RS-232 connector. The BIOS setup determines 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.

Pin Signal Pin Signal

1 RED 8 ORB_GND 2 GREEN 9 Fused VCC 3 BLUE 10 ORB_GND 4NC 11 NC 5 ORB_GND 12 DDCDAT 6 ORB_GND 13 HSYNC 7 ORB_GND 14 VSYNC

Caution

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 25 GND 13 NC 26 FHS

Appendix D – Replacing Flat Panel Display Bulbs

Appendix D – Replacing Flat p anel Display Bulbs

This appendix describes how to replace the bulbs in your flat panel display. We recommend you send the flat panel display to Xycom Automation for bulb replacement. However, if you would like to replace the bulbs on site, refer to the following 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.

3510 Units

Mitsubishi TFT Flat panel Display (model #AA104VB02)

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.

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

system board.

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 connectors from the inverter.

9. Gently lift the left side of the flat panel display, and disconnect the data interface

connector

10. Locate the bulb assembly on the left, outside edge of the flat panel display.

11. Referring to Figure D-1 insert a flat-bladed screwdriver between the bulb and the

clip to release the bulb.

12. Slide the bulb assembly out.

3500 Series Flat Panel Industrial PC

BULB ASSEMBLY

RELEASE CLIP

BULB ASSEMBLY

(PARTIALLY RETRACTED)

DISPLAY

ASSEMBLY

BULB ASSEMBLY

(PARTIALLY RETRACTED)

BULB ASSEMBLY

RELEASE CLIP

Figure D- 1. Model #AA104VB02 Bulb Assembly

13. Slide the new assembly into the opening from which the old assembly was

removed.

Note

Xycom Automation recommends replacing both bulbs at the same time.

14. Reverse steps 1 through 9 to reassemble the unit.

3512 and 3512 KP Units

Mitsubishi TFT Flat panel Display (Model #AA121SK12)

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.

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

system board.

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.

Appendix D – Replacing Flat Panel Display Bulbs

8. Disconnect the bulb connector from the inverter card.

9. Gently lift the left side of the flat panel display, and disconnect the data interface

connector.

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

3500 Series Flat Panel Industrial PC

BULB CONNECTOR

BULB ASSE M BLY (INSIDE)

DISPLAY MOUNTING SCREW LOCATIONS

FLAT PANEL DISPLAY

(FRONT VIEW)

BEZEL

DISPLAY MOUNTING SCREWS LOCATIONS

Figure D-2. Model #AA121SK12 Bulb Assembly – Front View

11. Referring to Figure D-3, insert a flat-bladed screwdriver between the bulb and

the clip and slide the bulb assembly out.

100

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