Eurotech GEMINI 1U ICE User manual

Issue D – March 2010 – ETH_GEMINI_1U_ICE_USM
DIGITAL TECHNOLOGIES FOR A BETTER WORLD
www.eurotech.com
USER MANUAL
GEMINI 1U ICE
19" 1U Rack Mount Industrial Compact Enclosure

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WARRANTY
For Warranty terms and conditions users should contact their local Eurotech Sales Office.
TRADEMARKS
All trademarks both marked and not marked appearing in this document are the property of their respective owners.
REVISION HISTORY
Issue no. PCB Date Comments
ANovember 2007 First full release of manual.
BMay 2008 Minor updates.
CAugust 2009 Minor updates and new branding.
DMarch 2010 Minor updates and layout changes.
© 2010 Eurotech Ltd. All rights reserved.
See Eurotech Worldwide Presence (on the back cover) for full contact details.

Table of contents
3
Table of contents
Important user information............................................................................................................................. 4
Safety notices and warnings .......................................................................................................................... 4
Life support policy .......................................................................................................................................... 5
CE notice........................................................................................................................................................ 5
WEEE............................................................................................................................................................. 5
RoHS.............................................................................................................................................................. 6
Technical assistance...................................................................................................................................... 6
Device labelling .............................................................................................................................................. 6
Internal battery ............................................................................................................................................... 6
Safe battery use ............................................................................................................................................. 6
Introduction...................................................................................................................................................... 7
GEMINI ICE specification............................................................................................................................... 8
GEMINI 1U ICE ‘at a glance’ ......................................................................................................................... 9
Features of the GEMINI ICE ........................................................................................................................ 11
Fan control ..................................................................................................................................................... 12
Connectors..................................................................................................................................................... 13
Internal configuration.................................................................................................................................... 20
PCI card module .......................................................................................................................................... 21
User status/display and navigation buttons ................................................................................................. 23
Front panel interface module ....................................................................................................................... 25
Front panel breakout module ....................................................................................................................... 27
Drive bay module ......................................................................................................................................... 28
Solid State Drive module.............................................................................................................................. 29
Dimension details......................................................................................................................................... 30
Weight details............................................................................................................................................... 30
Appendix A – EMC conformity ..................................................................................................................... 31
Eurotech Worldwide Presence..................................................................................................................... 32

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Important user information
In order to lower the risk of personal injury, electric shock, fire or equipment damage, users must
observe the following precautions as well as good technical judgment, whenever this product is
installed or used.
All reasonable efforts have been made to ensure the accuracy of this document; however, Eurotech
assumes no liability resulting from any error/omission in this document, or from the use of the
information contained herein.
Eurotech reserves the right to revise this document and to change its contents at any time without
obligation to notify any person of such revision or changes.
Safety notices and warnings
The following general safety precautions must be observed during all phases of operation, service, and
repair of this equipment. Failure to comply with these precautions or with specific warnings elsewhere
in this manual violates safety standards of design, manufacture, and intended use of the equipment.
Eurotech assumes no liability for the customer’s failure to comply with these requirements.
The safety precautions listed below represent warnings of certain dangers of which Eurotech is aware
of. You, as the user of the product, should follow these warnings and all other safety precautions
necessary for the safe operation of the equipment in your operating environment.
Installation in cupboards and safes
In the event that the product is placed within a cupboard or safe, together with other heat generating
equipment, ensure proper ventilation.
Do not operate in an explosive atmosphere
Do not operate the equipment in the presence of flammable gases or fumes. Operation of any
electrical equipment in such an environment constitutes a definite safety hazard.
Alerts that can be found throughout this manual
The following alerts are used within this manual and indicate potentially dangerous situations:
Danger, electrical shock hazard:
Information regarding potential electrical shock hazards:
Personal injury or death could occur. Also damage to the system, connected peripheral devices, or
software could occur if the warnings are not carefully followed.
Appropriate safety precautions should always be used, these should meet the requirements set out
for the environment that the equipment will be deployed in.
Warning:
Information regarding potential hazards:
Personal injury or death could occur. Also damage to the system, connected peripheral devices, or
software could occur if the warnings are not carefully followed.
Appropriate safety precautions should always be used, these should meet the requirements set out
for the environment that the equipment will be deployed in.
Information and/or Notes:
These will highlight important features or instructions that should be observed.

Important user information
5
Use an appropriate power supply
Only start the product with a power supply that conforms to the voltage requirements as displayed on
the voltage label attached to the system. In case of uncertainty about the required power supply,
please contact your local Eurotech Technical Support Team (see page 6) or the electricity authority.
Use power supplies that are compliant with SELV regulation.
Use certified power cables. The power cable must fit the product, the voltage and the required current.
Position cable with care, Avoid positioning cables in places where they may be trampled on or
compressed by objects placed on it. Take particular care of the plug, power-point and outlet of power
cable.
Avoid overcharging power-points.
Antistatic precautions
To avoid damage caused by ESD (Electro Static Discharge), always use appropriate antistatic
precautions when handing any electronic equipment.
Life support policy
Eurotech products are not authorized for use as critical components in life support devices or systems
without the express written approval of Eurotech.
CE notice
The product described in this manual is marked with the label in accordance with the 1999/5/EC
regulation.
Eurotech shall not be liable for use of its products with equipment (i.e. power supplies, personal
computers, etc.) that are not CE marked.
WEEE
The information below is issued in compliance with the regulations as set out in the 2002/96/EC
directive, subsequently superseded by 2003/108/EC. It refers electrical and electronic equipment and
the waste management of such products.
When disposing of a device, including all of its components, subassemblies and materials that are an
integral part of the product, you should consider the WEEE directive.
The symbol to the right has been attached to the equipment or, if this has not been
possible, on the packaging, instruction literature and/or the guarantee sheet. By using this
symbol, it states that the device has been marketed after August 13th 2005, and implies
that you must separate all of its components when possible, and dispose of them in
accordance with local waste disposal legislations.
Because of the substances present in the equipment, improper use or disposal of the refuse can cause
damage to human health and to the environment.
With reference to WEEE, it is compulsory not dispose of the equipment with normal urban refuse,
arrangements should be instigated for separate collection and disposal.
Contact your local waste collection body for more detailed recycling information.
In case of illicit disposal, sanctions will be levied on transgressors.

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RoHS
This device, including all it components, subassemblies and the consumable materials that are an
integral part of the product, has been manufactured in compliance with the European directive
2002/95/EC known as the RoHS directive (Restrictions on the use of certain Hazardous Substances).
This directive targets the reduction of certain hazardous substances previously used in electrical and
electronic equipment (EEE).
Technical assistance
For any technical questions, or if you cannot isolate a problem with your device, or for any enquiry
about repair and returns policies, feel free to contact your local Eurotech Technical Support Team.
See Eurotech Worldwide Presence (the back cover) for full contact details.
Transportation
When transporting any module or system, for any reason, it should be packed using anti-static material
and placed in a sturdy box with enough packing material to adequately cushion it.
Any product returned to Eurotech that is damaged due to inappropriate packaging will not be covered by the
warranty!
Device labelling
The GEMINI 1U ICE serial label is affixed to the end panel of the enclosure this contains the Eurotech
part number which in turn contains information on the version and issue of this product the label also
contains a serial number which is unique to each individual GEMINI 1U ICE.
The labels will also display product conformity marking.
Internal battery
The GEMINI SBC is fitted with a 3V Lithium battery that is used to maintain the GEMINI’s real time
clock and static RAM while the main supply is removed. The battery is fitted in a socket to allow easy
replacement. The battery has a service life of 5 years at +25°C (77°F).
Safe battery use
Lithium batteries that are found to be damaged, leaking, corroded or flat (low or no voltage) must be
disposed of in a safe manner following the relevant COSHH regulations.
Damaged, leaking, or corroded batteries (especially lithium batteries) must only be handled with caution.
Use non-conductive tools and wear suitable protection, e.g. safety glasses, rubber gloves, etc.
All faulty batteries must be segregated in a suitable, clearly marked non-conductive container. They must be
periodically disposed of by a recognised company specialising in the disposal of poisonous waste, who
comply with ‘The Disposal of Poisonous Waste Regulations Act.’
Replace with the same or equivalent type recommended by the manufacturer.
Dispose of batteries according to the manufacturer’s instructions.
Do not attempt to recharge, disassemble, heat above 100°C (212°F), or incinerate the Lithium battery.

Introduction
7
Introduction
The GEMINI 1U ICE system serves as a high performance, compact 19" rack mount ruggedised PC
system for applications in IT systems, machine control, and kiosk solutions. The GEMINI 1U ICE is
powered by an Intel Core 2 Duo / Core Duo / Core Solo / Celeron M processor based single board
computer designed and manufactured by Eurotech. The motherboard and system components are
designed for long life support with scalable CPU options from the Celeron M 440 1.86GHz for a wide
operating temperature, up to powerful server grade systems fitted with the Core 2 Duo T7400 2.16GHz
CPU.
This ruggedised system has a full compliment of PC features including quad Ethernet (with Gigabit
capability), USB ports, serial ports, multiple video outputs and a number of additional features for
creating secure systems. The system can also be fitted with 2 PCI add-on cards.
The front panel LCD display and navigation buttons can be used for user-defined configuration and
control for deeply ‘embedded systems’ which do not have access to a display. Please refer to the
GEMINI user manual for detailed information about the performance and operation of the GEMINI
SBC.

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GEMINI ICE specification
The GEMINI ICE includes the following standard features:
1U 19" standard ‘ruggedised’ enclosure.
Intel Core 2 Duo/Duo/Solo/Celeron M processor performance options.
Up to 3GB system DRAM.
Dual independent video with VGA / DVI / TV outputs.
Four 10/100/1000 base T Ethernet ports.
Three serial ports.
Six USB 2.0 compliant ports.
5.1 surround sound audio on standard Mic/Line-in/Line-out mini-jack connectors.
Front panel board providing a 2 line, 24 character LCD display, user LEDs and navigation
buttons.
PSU:180W integrated ATX supply or wide input range DC input.
Two PCI (rev 2.2) expansion slots via an internal flexible riser.
Internal DVD/CDRW drive. Speeds: 24x CD-R/CD-RW writing, 24x CD-ROM reading, 8x DVD-
ROM reading.
Option for USB Solid State Drive interfaced on the sixth USB port (not accessible on the front
panel in this case).
Option for up to two internal high shock resistant 2.5" SATA hard disk drives.
Operating temperature: +5°C to +55°C (41°F to 131°F).
Approximate weight: 6.0kg (13.20lbs).
EMC conformity: CE/FCC compliant (see page 31).
Safety compliance: UL, cUL, CB (power supply).
Configurations available include:
PSU options:
-AC version: Auto-ranging 90-265VAC, 47-63Hz, 180W Flex-ATX.
-DC version: 8-24VDC power input supply.
CPU options:
-Intel Celeron M 440 1.86 GHz.
-Intel Core Duo T2500 2 GHz.
-Intel Core 2 Duo T7400 2.16Ghz (64bit processor).
Memory options:
-Two 512MB PC5300 DDR2 SDRAM DIMM.
-Two 1GB PC5300 DDR2 SDRAM DIMM.
-2GB + 1GB PC5300 DDR2 SDRAM DIMM.
-Other processor, fan and memory options available on request. Please contact our sales
team for price and availability (see Eurotech Worldwide Presence).
Disk options:
-Mechanical 2.5inch SATA or IDE hard drive.
-Solid State USB flash module.
GEMINI 1U ICE (AC version) fitted with parallel port on SUBD25 instead of the two DB9 serial
ports COM2 and COM3.

Introduction
9
GEMINI 1U ICE ‘at a glance’
Front panel view (both AC and DC versions)
USB2.0 (x4) Ventilation holes User LEDs LCD display
On/Off HDD access DVD/CDRW User-defined label insert Navigation/Input
Reset
Rear panel views (AC version)
COM2 (RS232/422/485) COM3 (RS232) Audio
COM1 (RS232) Ethernet
DVI SVIDEO CVBS Mains
USB 2.0 x 2 VGA

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Rear panel views (DC version)
COM2 (RS232/422/485) COM3 (RS232) DVI SVIDEO
COM1 (RS232) Ethernet
CVBS Audio 8-24VDC input
USB 2.0 x 2 VGA

Introduction
11
Features of the GEMINI ICE
The GEMINI 1U high 19" Rack Mount enclosure offers the features listed below:
Front panel
On/Off momentary switch with integral blue power LED.
Access hole to recessed reset switch.
SATA/IDE access activity LED.
Four USB 2.0 ports (down to 3 if VSSD in use).
Ventilation hole (cool air flows into the GEMINI ICE).
Slot-loading DVD/CDRW drive.
User-defined ‘identification’ label and status LED’s.
LCD character display – 2 rows x 24 characters (with blue backlight).
User navigation and input switches.
Rear panel
Two PCI card breakout positions.
Three serial ports (2x RS232 and 1x RS232/422/485).
Four 10/100/1000 Ethernet ports (Gigabit Ethernet).
Three stereo audio jacks (supporting 5.1 outputs).
Two USB 2.0 ports.
One VGA connector.
One DVI port.
One SVideo output.
One video composite output.
AC input (IEC connector) or DC input connector.
PSU fan.
Additional features
The GEMINI ICE also has an internal hard disk drive and/or an USB flash module.

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Fan control
There are two fans in the GEMINI 1U ICE constantly spinning at maximum speed, the CPU fan, and
the system fan.
The AC PSU’s fan is thermally controlled. It therefore runs at a speed proportional to the power
consumption.
There is also a controllable system fan supplied in the GEMINI 1U ICE which helps to cool down the
PCI cards and to extract warm air out of the box. It might be required to turn it on when one or two
high-power PCI cards dissipating some additional heat are fitted. This extra fan is controlled by the FPI
board and its command is automated so the system decides whether the fan needs to speed up or
slow down.
Control of the system fan is implemented using drivers supplied by Eurotech. These functions are fully
programmable and are available as user-defined controls for OEM customers. Drivers are available for
Windows XP and Linux.
Contact Eurotech Technical Support for further information (see page Eurotech Worldwide Presence).

Connectors
13
Connectors
The connectors on the GEMINI let you connect external devices such as keyboards, mouse devices,
printers etc.
Connector Function See …
COM1 Serial port 1 (RS232) Page 15.
COM2 Serial port 2 (RS232/422/485) Page 15.
COM3 Serial port 3 (RS232) Page 15.
ETH1/2/3/4 Ethernet ports 10/100/1000Mb/s Page 15.
LINE_IN Audio line in Page 16.
MIC Micro in Page 16.
LINE_OUT Audio line out Page 17.
USB1/2 USB ports 1 and 2 Page 17.
VGA VGA monitor Page 17.
DVI DVI monitor Page 18.
SVIDEO Super video out Page 18.
VIDEO Composite video out Page 18.
DC DC input source Page 19.
The connectors are illustrated in the following diagrams.

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AC version
MIC USB1
COM2 COM3 LINE_IN LINE_OUT DVI SVIDEO CVBS
COM1 ETH1 ETH2 ETH3 ETH4 USB2 VGA
DC version
USB1 MIC
COM2 COM3 DVI SVIDEO CVBS LINE_IN LINE_OUT
COM1 ETH1 ETH2 ETH3 ETH4 USB2 VGA
Further details about these connectors are provided in the following sections.

Connectors
15
COM1/2/3 – RS232 serial ports (RS422/485 option on COM2 only)
DB9 male
Pin Signal name Pin Signal name
1 DCD/422TX-/485- 2 RXD/422TX+/485+
3 TXD/422RX+ 4 DTR/422RX-
5 Ground 6 DSR
7 RTS 8 CTS
9 RI
ETH1/2/3/4 – LAN
RJ-45 10/100/1000Mb/s.
Pin
Signal name
(10/100)
Signal name
(10/100/1000)
1 TX+ MD0+
2 TX- MD0-
3 RX+ MD1+
4 No Connect MD2+
5 No Connect MD2-
6 RX- MD1-
7 No Connect MD3+
8 No Connect MD3-
For a Gigabit Ethernet connection the network cable should be a CAT5 or above and include all four
pairs.
96
5
1

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LINE_IN, MIC, LINE_OUT – Audio connectors
3.5mm stereo audio jacks are used for audio connection. The audio codec can operate in either of the
following modes:
2.0 mode, which allows for microphone in, line in and line out operation.
5.1 mode, which provides six-channel surround sound output. The microphone input and line
in are not available during six channel mode.
Selection of 2.0 or 5.1 mode is made under software control.
The audio connectors are illustrated in the following diagram:
The pin settings for each connector are described in the following sections.
LINE_IN - 3.5mm stereo jack
PC99 colour: light blue.
Pin Signal name 2.0 mode Signal name 5.1 mode
Tip Line in left Rear surround left
Ring Line in right Rear surround right
Sleeve Ground Ground
MIC - 3.5mm stereo jack
PC99 colour: pink.
Pin Signal name 2.0 mode Signal name 5.1 mode
Tip Microphone 2 Low frequency effects
Ring Microphone 1 Surround centre
Sleeve Ground Ground
LINE_OUT- 3.5mm stereo jack
PC99 colour: lime.
Pin Signal name 2.0 mode Signal name 5.1 mode
Tip Line out left Front surround left
Ring Line out right Front surround right
Sleeve Ground Ground
Ring
Sleeve Tip
Sleeve
Tip
Ring

Connectors
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USB1/2 – USB ports 1 and 2
USB type A connector.
Pin Signal name
1 VBUS
2 Data-
3 Data+
4 Ground
VGA – VGA connector
DB15 Female
PC99 colour: Blue
Pin Signal name Pin Signal name
1 Red 2 Green
3 Blue 4 No Connect
5 Ground 6 Ground
7 Ground 8 Ground
9 +5V (Fused) 10 Ground
11 No Connect 12 DDCSDA
13 Hsync 14 Vsync
15 DDCSCL
51
15 11
10 6

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DVI – DVI connector
DVI-I (Digital Visual Interface – Digital single link & Analogue)
Pin Signal name Pin Signal name
1 TMDS D2– 13 No Connect
2 TMDS D2+ 14 +5V Power
3 TMDS D2
Shield
15 Ground
4 No Connect 16 Hot Plug
Detect
5 No Connect 17 TMDS D0–
6 DDC Clock 18 TMDS D0+
7 DDC Data 19 TMDS D0
Shield
8 Vertical
Synchro
20 No Connect
9 TMDS D1– 21 No Connect
10 TMDS D1+ 22 TMDS Clock
Shield
11 TMDS D1
Shield
23 TMDS Clock+
12 No Connect 24 TMDS Clock–
C1 Analogue Red C2 Analogue
Green
C3 Analogue Blue C4 Horizontal
Synchro
C5 Analogue
Ground
The analogue video signals are shared with the VGA connector, so you cannot connect an analogue monitor
to the DVI port if a VGA monitor is already plugged in the VGA connector..

Connectors
19
SVIDEO – Super video out
S-VHS 4-pin mini-DIN connector.
Pin Signal name
1 GND
2 GND
3 Y
4 C
VIDEO – CVBS video out
RCA video connector.
Pin Signal name
1 CVBS
2 GND
DC – DC input source
COMBICON power connector.
Pin Signal name
1 DC_IN1
2 CHASSIS
3 GND
The maximum voltage range allowed by the DC input is 8 to 24VDC. The power rating of the DC input
source must be chosen in accordance to the maximum power consumption of the GEMINI 1U ICE.
Worst case: 100 Watts (figure taken with T7400 processor stressed to the absolute maximum power
and with two additional PCI cards in operation)
The DC input does not have any polarisation protection.
1The CHASSIS pin can be either left unconnected or connected to the network earth, but it must not be shorted
with GND (pin3) in order not to override the EMC filter.

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Internal configuration
Refer to Eurotech Worldwide Presence before proceeding any further.
The internal components of the unit must only be accessed by suitably qualified personnel using anti-static
equipment. The power supply must be switched off and the AC or DC input cable unplugged.
The following diagram illustrates the construction of the GEMINI ICE.
PSU GEMINI SBC PCI card (x2) module
Breakout board Drive bay module LCD and front panel interface board
The following sections describe features of the highlighted areas above.