Curtiss-Wright DuraCOR 80-40 User manual

USER MANUAL
DuraCOR 80-40
Rugged Modular Core i7 Mission Computer with PCI
Express Expansion and Dual Gi
g
E
DUCOR-80-40-XX
MNL-0642-01 Rev A5 ECO-5370 Effective: 19 Jan 18

DuraCOR 80-40 User Manual
Page 2 of 59 MNL-0642-01 Rev A5 ECO-5370 19 Jan 18
Disclaimer
Although the information contained herein has been carefully verified, Parvus Corporation assumes no responsibility for errors that
might appear in this document or for damage to property or persons resulting from improper use of this manual or related software.
Parvus reserves the right to change the contents and form of this document, as well as the features and specifications of its
products, at any time without notice. The information in this publication does not represent a commitment on the part of Parvus. This
document contains proprietary information that is protected by copyright. All rights are reserved. No part of this document may be
photocopied, reproduced, or translated into another language without the prior written consent of Parvus.
Contact Information
Parvus Corporation
3222 S. Washington St.
Salt Lake City, Utah, USA 84115
Phone: [phone]
Toll-Free: [phone]
Fax: [phone]
Email:
Sales: [email protected]
Support: [email protected]
Web-site: http://www.parvus.com
Send us your comments and feedback: [email protected]
Trademarks
All trademarks, both marked and not marked, appearing in this document are the property of their respective owners.
Copyright
© 2013 Parvus Corporation

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Table of Contents
Chapter 1 Introduction .............................................................................................................6
About This Document....................................................................................................................................6
Manual Organization ..............................................................................................................................6
Description of Safety Symbols................................................................................................................7
Overview .......................................................................................................................................................8
Features..................................................................................................................................................9
High Performance CPU....................................................................................................................9
Connectivity and I/O.........................................................................................................................9
Rugged Mechanical Design.............................................................................................................9
Modular / Expandable......................................................................................................................9
Functional Description.................................................................................................................................10
Configurations.......................................................................................................................................11
Base System Interconnect Block Diagram...........................................................................................12
Expansion Segments............................................................................................................................13
Parvus Power Supply...........................................................................................................................14
CPU Block Diagram..............................................................................................................................15
Chapter 2 Operating Description...........................................................................................16
Connecting to the DuraCOR 80-40.............................................................................................................16
Device Connection ...............................................................................................................................16
System Connectors ..............................................................................................................................17
Starter Cableset for Base Unit..............................................................................................................18
Mounting the System............................................................................................................................18
Installing Cards in the Expansion Segments ..............................................................................................19
Removing Modules...............................................................................................................................19
Reconnecting Modules.........................................................................................................................19
Removing a Board................................................................................................................................20
Installing Custom Boards......................................................................................................................21
Basic Operating Procedures.......................................................................................................................23
Power-on Sequence.............................................................................................................................23
Running the BIOS Setup Utility ............................................................................................................24
Hot-Swappable SATA Drives.........................................................................................................24
HDMI Audio....................................................................................................................................24
Testing the GPIO..................................................................................................................................24
Using SSDs.................................................................................................................................................25
SSD Mounting Tray..............................................................................................................................26
Factory-Mounted SSDs..................................................................................................................26
Mounting an SSD in the Mounting Tray.........................................................................................27
Hot-Swapping the SSDs.......................................................................................................................27
Zeroization...................................................................................................................................................28
Chapter 3 Connector Descriptions........................................................................................29
Connector Specifications......................................................................................................................29
J1 Power Connector Pinouts................................................................................................................29
J11 CPU-A Connector Pinouts.............................................................................................................30
J12 CPU-B Connector Pinouts.............................................................................................................32
GPIO Connector Pinouts......................................................................................................................34
J13 Standard Expansion Segment.......................................................................................................35
J14 Standard Expansion Segment.......................................................................................................37

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Chapter 4 Specifications........................................................................................................40
Mechanical Specifications...........................................................................................................................40
Weight...................................................................................................................................................40
Construction..........................................................................................................................................40
Dimensions...........................................................................................................................................40
Base Unit Dimensions....................................................................................................................40
Base Unit With One Expansion Segment (EXP) Dimensions........................................................45
Base Unit With Two Expansion Segments (EXP) Dimensions......................................................47
Mounting Instructions ...........................................................................................................................49
Vertical Mounting ...........................................................................................................................49
Horizontal Mounting.......................................................................................................................49
Technical Specifications..............................................................................................................................51
High Performance Processor ...............................................................................................................51
RAM Memory........................................................................................................................................51
Solid State Disk ....................................................................................................................................51
Operating System.................................................................................................................................51
Bus Architecture ...................................................................................................................................51
Expansion I/O Support .........................................................................................................................51
Network.................................................................................................................................................52
Serial.....................................................................................................................................................52
USB ......................................................................................................................................................52
Video.....................................................................................................................................................52
Audio.....................................................................................................................................................52
DIO .......................................................................................................................................................52
PS2.......................................................................................................................................................52
Power....................................................................................................................................................52
Environmental Specifications......................................................................................................................54
Temperature...................................................................................................................................54
Shock/Vibration..............................................................................................................................54
Operating Conditions .....................................................................................................................54
EMI/EMC Isolation................................................................................................................................54
Reliability ..............................................................................................................................................55
Software Specifications...............................................................................................................................55
Chapter 5 Troubleshooting....................................................................................................56
Product Identification...................................................................................................................................56
Technical Assistance ..................................................................................................................................56
Returning for Service ..................................................................................................................................56
Chapter 6 Contact Info ...........................................................................................................57
Appendix A Power Supply.....................................................................................................58

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List of Figures
Figure 1. Mission Computer (DUCOR-80-40-00).........................................................................................8
Figure 2. Mission Computer with Expansion Segments (DUCOR-80-40-10/20).........................................8
Figure 3. Functional Diagram.....................................................................................................................10
Figure 4. Base System Interconnect Block Diagram .................................................................................12
Figure 5. Expansion Segment System Interconnect Block Diagram.........................................................13
Figure 6. Power Supply Block Diagram.....................................................................................................14
Figure 7. CPU Block Diagram....................................................................................................................15
Figure 8. Example Device Connections.....................................................................................................16
Figure 9. System Connectors ....................................................................................................................17
Figure 10. Base System Starter Cableset (CBL-80-40-00) .......................................................................18
Figure 11. Removing Modules...................................................................................................................19
Figure 12. Removing Boards from an EXP................................................................................................20
Figure 13. Empty EXP................................................................................................................................21
Figure 14. Internal Dimensions of an EXP.................................................................................................21
Figure 15. Board Stack in an EXP .............................................................................................................22
Figure 16. SSD Bay ...................................................................................................................................25
Figure 17. Empty SSD Mounting Tray.......................................................................................................27
Figure 18. Connector J1 Power.................................................................................................................29
Figure 19. Connector J11 CPU-A..............................................................................................................30
Figure 20. Connector J12 CPU-B..............................................................................................................32
Figure 21. Connector J13...........................................................................................................................35
Figure 22. Connector J14...........................................................................................................................37
Figure 23. Base Unit Angle View ...............................................................................................................40
Figure 24. Base Unit Front View................................................................................................................41
Figure 25. Base Unit Side View .................................................................................................................42
Figure 26. Base Unit Rear View.................................................................................................................43
Figure 27. Base Unit Top View ..................................................................................................................44
Figure 28. Base Unit with One EXP Angle View........................................................................................45
Figure 29. Base Unit with One EXP Front and Side Views .......................................................................45
Figure 30. Base Unit with One EXP Rear View.........................................................................................46
Figure 31. Base Unit with Two EXPs Angle View......................................................................................47
Figure 32. Base Unit with Two EXPs Front and Side Views......................................................................47
Figure 33. Base Unit with Two EXPs Rear View .......................................................................................48
Figure 34. Vertical Mounting Holes............................................................................................................49
Figure 35. Horizontal Mounting Holes Base Unit.......................................................................................49
Figure 36. Horizontal Mounting Holes Base Unit with 1 EXP....................................................................50
Figure 37. Horizontal Mounting Holes Base Unit with 2 EXPs ..................................................................50
Figure 38. Horizontal Mounting Holes Base Unit with 2 EXPs ..................................................................58

Chapter 1 Introduction DuraCOR 80-40 User Manual
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Chapter 1 Introduction
The DuraCOR® 80-40 is a rugged Commercial-Off the Shelf (COTS) tactical mission computer
subsystem based on the high performance Intel Core i7 Sandy Bridge processor in an ultra-rugged
chassis optimized for harsh military and civil vehicle/aircraft installations. The DuraCOR 80-40 features a
hinged panel on the rear with two slots for removable 2.5” SATA Solid State Disks (SSD). The mission
computer can be ordered with one or two optional I/O expansion units for PCIe 104 and/or PC/104-Plus
I/O cards.
About This Document
This manual provides the technical information necessary to take advantage of all features and integrate
the mission computer in diverse platforms and applications.
Manual Organization
Chapter 1 provides a functional description of the DuraCOR 80-40, and explains how expansion
segments are integrated with the base system to provide additional I/O.
Chapter 2 explains how to operate the DuraCOR 80-40. It describes the system connectors and
cables, and includes procedures for starting the system, using the hot-swappable SSD drives,
installing and using cards in the expansion segments, adding zeroization capabilities, and
modifying BIOS settings.
Chapter 3 contains connector pinouts for all connectors.
Chapter 4 provides chassis specifications, dimensions, and mounting instructions for all
DuraCOR 80-40 configurations. In addition, it provides the technical and environmental
specifications for the DuraCOR 80-40.
Chapters 5 and 6 provide troubleshooting and Parvus contact information.

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Description of Safety Symbols
The following safety symbols are used in this manual and indicate potentially dangerous situations.
Warning! Danger, electrical shock hazard!
Personal injury or death could occur. Also damage to the system, connected peripheral devices, or
software could occur if the warnings are not followed carefully.
Caution! Hazard to individuals, environment, devices, or data!
If you do not adhere to the safety advice next to this symbol, there is obvious hazard to individuals, to
environment, to materials, or to data.
Note: This symbol highlights important information or instructions that should be observed.

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Overview
The DuraCOR® 80-40 is a rugged Commercial-Off the Shelf (COTS) tactical mission computer
subsystem based on the high performance Intel Core i7 Sandy Bridge processor with a high-speed,
stackable PCI-Express bus (PCIe/104) architecture for I/O card expansion. Optimally designed for Size,
Weight, and Power (SWaP)-sensitive mobile, airborne, ground, manned or unmanned vehicle
applications, the DuraCOR 80-40 combines powerful graphics and multi-core processing with ultra-
reliable mechanical robustness and modular I/O expansion for extreme environmental and EMI
performance per MIL-STD-810G, DO-160G, MIL-STD-461F, MIL-STD-704F, and MIL-STD-1275D.
Delivering new capabilities for C4ISR command and control, image processing and surveillance
requirements, the DuraCOR 80-40 features modular interlocking chassis segments with pre-installed MIL-
DTL-38999 connectors and an internal power/control bus to ease the integration of application-specific
PCIe/104 or PCI/104-Express I/O cards and meet high-speed mission payload I/O requirements.
Standard I/O includes 2x Gigabit Ethernet, 6x USB, 2x RS232, 16-bit GPIO, dual display outputs (Analog,
DVI), stereo audio, PS2, and a stackable PCIe/104 bus. The unit mounts either horizontally or vertically
and supports factory integration of the Cisco IOS-managed DuraMAR 5915 router and/or application I/O
into a single appliance combination of computer + router + switch + application I/O.
The DuraCOR 80-40 is completely sealed (IP67), requires no active cooling, includes a military-grade
power supply supporting aircraft (MIL-STD-704F) and ground vehicle (MIL-STD-1275D) voltages, and
features a hinged panel on the rear with two slots for removable 2.5” SATA Solid State Disks (SSD).
Parvus application engineering services are available to support semi-customized configurations,
including mechanical changes and pre-integrated PCIe/104 I/O cards.
The DuraCOR 80-40 is available as either:
A standalone mission computer (Figure 1)
A mission computer with one or two expansion segments (EXP) factory-installed
Figure 2)
Figure 1. Mission Computer
(DUCOR-80-40-00)
Figure 2. Mission Computer with
Expansion Segments (DUCOR-80-40-10/20)

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Features
High Performance CPU
Intel 2nd Generation Core i7 (Sandy Bridge) Processor, 2.2 GHz , Dual-Core, 4-8 GB DRAM with
Integrated GPU and Advanced Vector Extensions (AVX) Signal Processing
Connectivity and I/O
2x Gigabit Ethernet 10/100/1000 Mbps LAN Interfaces
6x USB 2.0, 2x RS-232 Serial, 16x Discrete DIO
VGA/Analog Video, HDMI, Stereo Audio, PS2
Dual Slots for Removable 2.5’’ SATA Solid State Disks (SSDs) (on rear)
Other I/O Configurations by Special Order (i.e., MIL-STD-1553/429)
Rugged Mechanical Design
Designed for MIL-810G Shock, Vibration, Thermal, Altitude, Humidity
-40to +71C Fanless Extended Temp Operation with No Moving Parts
Corrosion-Resistant, Aluminum Chassis Sealed Against Water, Dust, EMI
Sealed, Hinged Panel on Rear for Dual Removable SATA SSD Storage
Circular MIL-DTL-38999 Connectors for Reliable I/O Connections
Filtered, Transient-Protected Power Supply for Aircraft and Vehicle Use
Qualified to MIL-461F and DO-160G Conducted/Radiated Emissions & Susceptibility
Conformal Coating for Humidity/Tin-Whisker Mitigation
Flexible / Robust Mounting - Base Flange Mount or Side Boss Mount
Modular / Expandable
Modular Interlocking Chassis Design Supports Stackable PCIe104 I/O Card Expansion for High
Speed Interconnect (2-3 Card Slots Per Expansion Chassis Segment)
Pre-Installed MIL-38999 Connectors and Internal Power/Control Bus Ease Integration of
PCIe/104 or PCI/104-Express Cards by Parvus Factory
Factory Mateable with DuraMAR 5915 Router for Computer + Router + Switch Appliance

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Functional Description
The DuraCOR 80-40 is a rugged expandable mission computer based on a Dual-Core 2nd Generation
Core i7 (Sandy Bridge), 2.2 GHz processor.
The power supply used on the DuraCOR 80-40 has been designed to satisfy the expandability and
customization needs of the system. The integration of power-demanding modules such as GPUs, frame
grabbers, and high performance switches and/or router is possible because of more than 100W of power
head-room.
The 2-slot storage compartment allows the removal and installation of 2.5” SATA interface media.
Optional SSD drives provide a high- performance storage solution in the most demanding environments.
Standard additional expansion segments can be added to the system. Integration and/or customization
services are available through the Application Engineering team.
Figure 3. Functional Diagram

GigE LAN x2
RS-232 Serial x2
USB 2.0 x6
VGA
DVI/HDMI
GPIO (16-bit)

Ke
y
board & Mouse

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Configurations
Product Product Number Breakout
Cableset Description
Mission Computer DuraCOR 80-40-00 CBL-80-40-00 DuraCOR 80-40, 2.2GHz, Corei7-2655LE, 8GB RAM
Mission Computer with 1
Expansion Segment DuraCOR 80-40-10 CBL-80-40-00, DTK-80-40-0X* DuraCOR 80-40, 2.2GHz, Corei7-2655LE, 8GB RAM, 1x Expansion Segment
Mission Computer with 2
Expansion Segments DuraCOR 80-40-20 CBL-80-40-00, DTK-80-40-0X* DuraCOR 80-40, 2.2GHz, Corei7-2655LE, 8GB RAM, 2x Expansion Segment
* DTK-80-40-00 = Development Kit for CentOS Linux
DTK-80-40-01 = Development Kit for WIN7-Pro64

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Base System Interconnect Block Diagram
The DuraCOR 80-40 is built with modular interlocking chassis segments to support multiple
configurations. The DuraCOR 80-40 base system consists of the CPU module and the power supply
module. Each module contains a PCB that provides an internal power/control bus that interconnects the
modules, provides Ethernet and zeroization signals, and supplies power.
Figure 4. Base System Interconnect Block Diagram
The Parvus Power Supply provides power for the CPU and for boards in the expansion
segments (if any).
The internal Ethernet connection is used for communication between modules.
The Zeroization signal is externally generated at the J3 Console connector and transmitted to
the CPU and to boards in the expansion segments. See "Zeroization" on page 28 for more
details.

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Expansion Segments
In expansion segment configurations, additional modules are added between the CPU and power supply.
Figure 5 shows a base system with two expansion segments. Depending on the configuration ordered,
the expansion segments may be pre-populated with a variety of I/O boards, or empty (for customer
installation of boards).
Figure 5. Expansion Segment System Interconnect Block Diagram

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Parvus Power Supply
The bottom board is a Parvus power supply. The rugged, isolated power supply is capable of supplying
power output over extended temperature ranges (-40 to +71C per MIL-STD-810G). Featuring a rugged
mechanical design, this power supply is designed to operate without any active cooling and provide
resistance to high levels of shock and vibration.
Features
• 28V Nominal Power Input Voltage (12-36 VDC Continuous <100 W Systems; 18-36 VDC for up
to 150W Systems)
• Reverse, Over Voltage, 250V Spike, 100V Surge-Protected (MIL-STD-704F and MIL-STD-
1275D Compliance)
• < 50 W Maximum Power Consumption (Base System); ~100 W Available for I/O Expansion
Modules
• Grounding Lug for Connection to System Chassis Ground (¼” - 20 UNC)
Figure 6. Power Supply Block Diagram

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CPU Block Diagram
Figure 7. CPU Block Diagram

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Chapter 2 Operating Description
This chapter describes the operation of the DuraCOR 80-40 base unit and expansion segments.
All gaskets are made with fluorosilicone to prevent fungus growth while protecting the system against
humidity, and dust. Moreover, EMI gaskets are Al-Ag-filled fluorosilicone to seal the system against EMI.
Connecting to the DuraCOR 80-40
Device Connection
Figure 8 shows several examples of typical connections that can be made with the DuraCOR 80-40
mission computer.
Figure 8. Example Device Connections

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System Connectors
Figure 9 shows the connectors on the front panel of a DuraCOR 80-40 with two expansion segments. In
all configurations, the CPU connectors are on top and the power connector is on the bottom.
Figure 9. System Connectors
Note: Connectors are sealed only when mating connectors or protective caps are installed.

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Starter Cableset for Base Unit
You should test the DuraCOR 80-40 and cabling or interfaces prior to installation in the target system to
ensure full operational capability. Full bench-top testing can be performed by using the Parvus starter
cableset available for this unit or by using a custom set of cables made specifically for the intended target
system, vehicle, or craft. Refer to Chapter 3 for pinouts and descriptions.
The Parvus starter cableset (CBL-80-40-00) for the base unit is available for purchase through the Parvus
Sales department and is meant for lab or bench testing purposes only. The cables break out I/O from the
CPU (connectors J11 and J12) and power (J1) to standard PC-style interfaces.
Figure 10. Base System Starter Cableset (CBL-80-40-00)
The starter cableset for the base system includes the following cables.
Cable Type Quantity Description
Power CBL-2500 Banana Plugs 3 each J1 Power
CPU-A CBL-2498 J11 Ports, CPU-A
HD 15-Pin, female 1 each VGA
PS2 2 each PS2 Keyboard and PS2 Mouse
DB9, male 2 each Serial COM1 and COM2
3.5mm Stereo Jack 1 each Audio
19-Pin HDMI Type A, female 1 each DVI/HDMI
CPU-B CBL-2499 J12 Ports, CPU-B
RJ-45 Connectors with Couplers 2 each LAN
USB Type A, female 6 each USB 2.0
2 x 10 IDC 1 each 16-Bit GPIO
Mounting the System
After testing is complete, you can mount the DuraCOR 80-40 on the system. Refer to "Mounting
Instructions" in Chapter 4.

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Installing Cards in the Expansion Segments
To access an expansion segment for board removal or installation, you must remove the modules above
the expansion segment.
Removing Modules
The modules attach to each other by 8-32 screws at the four corners of each module.
Figure 11. Removing Modules
1. Disconnect the power connector from J1 on the power supply module.
2. Working from the top down, remove the screws (not the heat sink screws) and washers from the top.
3. Lift the top cover straight up.
4. Remove the screws and washers, and lift off the CPU module.
5. If you need to access the bottom card slot in an expansion segment, remove the screws and
washers, and lift the EXP so that the bottom side of the EXP is accessible.
Reconnecting Modules
Modules must always be placed in the same order from bottom to top: power supply, EXP1 (if used),
EXP2 (if used), and CPU module on the top.
1. Position the lowest module over the power supply.
2. Align the connectors on the module with the connectors on the power supply.
3. Carefully mate the module to the power supply.
4. Screw the two modules together at each corner using the 8-32 screws and washers, torque 15.5
in-lbs.
5. Follow the same procedure to connect any other modules and the cover.
6. Reconnect the power cable to connector J1 on the power supply module.
Remove CPU
module screws (4)

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Removing a Board
This section provides the general procedure for removing a board from an EXP.
7. Disconnect any cables from the IO board to the board..
8. Remove any spacers and bus extenders from the board.
9. Remove the screws securing the board to the card slot.
Figure 12. Removing Boards from an EXP
Bus Extenders,
Spacers
IO PCB
Screws
(on bottom)
Cables from Board to PCB