Octagon Systems 2040 PC/104 CPU User manual

O C T A G O N S Y S T E M S
Embedded PCs For Extreme Environments
2040 PC/104 CPU
User’sManual
5167 (1099)

DiskOnChip®is a registered trademark of M–Systems. LynxOS®is a registered
trademark of Lynx Real–Time Systems, Inc. Micro PC™, PC SmartLink™, Octagon
Systems Corporation®, the Octagon logo and the Micro PC logo are trademarks of
Octagon Systems Corporation. PICO FA™ is a trademark of Phoenix Technologies
Ltd. QuickBASIC®is a registered trademark of Microsoft Corporation. QNX®is a
registered trademark of QNX Software Systems Ltd. ROM–DOS™ is a trademark of
Datalight. Windows 98™, Windows NT™, and Windows CE™ are trademarks of
Microsoft Corporation.
Copyright 1999—Octagon Systems Corporation. All rights reserved. However, any part
of this document may be reproduced, provided that Octagon Systems Corporation is
cited as the source. The contents of this manual and the specifications herein may
change without notice.
The information contained in this manual is believed to be correct. However, Octagon
assumes no responsibility for any of the circuits described herein, conveys no license
under any patent or other right, and makes no representations that the circuits are free
from patent infringement. Octagon makes no representation or warranty that such
applications will be suitable for the use specified without further testing or modification.
Octagon Systems Corporation general policy does not recommend the use of its products
in life support applications where the failure or malfunction of a component may directly
threaten life or injury. It is a Condition of Sale that the user of Octagon products in life
support applications assumes all the risk of such use and indemnifies Octagon against
all damage.
R
Technical support: 303–426–4521
Telephone: [phone]
FAX: [phone]
Web site: www.octagonsystems.com
6510 W. 91st Ave.
Westminster, CO 80030

2040PC/104CPUuser’smanual Notice to user
IMPORTANT!
Please read the following section before installing your product:
Octagon’sproductsaredesignedtobehighinperformancewhileconsuming
very little power. In order to maintain this advantage, CMOS circuitry is
used.
CMOSchipshavespecificneedsandsomespecialrequirementsthattheuser
mustbeawareof.Read thefollowingtohelpavoiddamage to yourcardfrom
the use of CMOS chips.
≡≡
≡≡
≡Using CMOS circuitry in industrial control
Industrial computers originally used LSTTL circuits. Because many PC
components are used in laptop computers, IC manufacturers are exclu-
sively using CMOS technology. Both TTL and CMOS have failure
mechanisms, but they are different. Described below are some of the
failures which are common to all manufacturers of CMOS equipment.
However, much of the information has been put in the context of the
Micro PC.
Octagon has developed a reliable database of customer–induced, field
failures. The average MTBF of Micro PC cards exceeds 11 years, yet
there are failures. Most failures have been identified as customer–
induced, but there is a small percentage that cannot be identified. As
expected, virtually all the failures occur when bringing up the first
system. On subsequent systems, the failure rate drops dramatically.
nApproximately 20% of the returned cards are problem–free. These
cards, typically, have the wrong jumper settings or the customer has
problems with the software. This causes frustration for the customer
and incurs a testing charge from Octagon.
nOf the remaining 80% of the cards, 90% of these cards fail due to
customer misuse and accident. Customers often cannot pinpoint the
cause of the misuse.
nTherefore, 72% of the returned cards are damaged through some
type of misuse. Of the remaining 8%, Octagon is unable to determine
the cause of the failure and repairs these cards at no charge if they
are under warranty.

Notice to user 2040PC/104CPUuser’smanual
The most common failures on CPU cards are over voltage of the power
supply, static discharge, and damage to the serial and parallel ports. On
expansion cards, the most common failures are static discharge, over
voltage of inputs, over current of outputs, and misuse of the CMOS
circuitry with regards to power supply sequencing. In the case of the
video cards, the most common failure is to miswire the card to the flat
panel display. Miswiring can damage both the card and an expensive
display.
nMultiple component failures: The chance of a random compo-
nent failure is very rare since the average MTBF of an Octagon card
is greater than 11 years. In a 7 year study, Octagon has never found
a single case where multiple IC failures were not caused by misuse
or accident. It is very probable that multiple component failures
indicate that they were user–induced.
nTesting “dead” cards: For a card that is “completely nonfunc-
tional”, there is a simple test to determine accidental over voltage,
reverse voltage or other “forced” current situations. Unplug the card
from the bus and remove all cables. Using an ordinary digital ohm-
meter on the 2,000 ohm scale, measure the resistance between
power and ground. Record this number. Reverse the ohmmeter leads
and measure the resistance again. If the ratio of the resistances is
2:1 or greater, fault conditions most likely have occurred. A common
cause is miswiring the power supply.
nImproper power causes catastrophic failure: If a card has had
reverse polarity or high voltage applied, replacing a failed compo-
nent is not an adequate fix. Other components probably have been
partially damaged or a failure mechanism has been induced. There-
fore, a failure will probably occur in the future. For such cards,
Octagon highly recommends that these cards be replaced.
nOther over–voltage symptoms: In over–voltage situations, the
programmable logic devices, EPROMs and CPU chips, usually fail in
this order. The failed device may be hot to the touch. It is usually the
case that only one IC will be overheated at a time.
nPower sequencing: The major failure of I/O chips is caused by the
external application of input voltage while the Micro PC power is off.
If you apply 5V to the input of a TTL chip with the power off, noth-
ing will happen. Applying a 5V input to a CMOS card will cause the
current to flow through the input and out the 5V power pin. This
current attempts to power up the card. Most inputs are rated at
25 mA maximum. When this is exceeded, the chip may be damaged.
nFailure on powerup: Even when there is not enough current to
destroy an input described above, the chip may be destroyed when
the power to the card is applied. This is due to the fact that the input
current biases the IC so that it acts as a forward biased diode on
powerup. This type of failure is typical on serial interface chips.

2040PC/104CPUuser’smanual Notice to user
nHot insertion: Plugging cards into the card cage with the power on
will usually not cause a problem. (Octagon urges that you do not
do this!) However, the card may be damaged if the right sequence
of pins contacts as the card is pushed into the socket. This usually
damages bus driver chips and they may become hot when the power
is applied. This is one of the most common failures of expansion
cards.
nTerminated backplanes: Some customers try to use Micro PC
cards in backplanes that have resistor/capacitor termination net-
works. CMOS cards cannot be used with termination networks.
Generally, the cards will function erratically or the bus drivers may
fail due to excessive output currents.
nExcessive signal lead lengths: Another source of failure that was
identified years ago at Octagon was excessive lead lengths on digital
inputs. Long leads act as an antenna to pick up noise. They can also
act as unterminated transmission lines. When 5V is switched onto
a line, it creates a transient waveform. Octagon has seen
submicrosecond pulses of 8V or more. The solution is to place a
capacitor, for example 0.1 µF, across the switch contact. This will
also eliminate radio frequency and other high frequency pickup.
≡≡
≡≡
≡Avoiding damage to the heatsink/CPU
WARNING!
When handling any Octagon CPU card, extreme care must be taken
not to strike the heatsink (if installed) against another object, such
as a table edge. Also, be careful not to drop the CPU card, since this
may cause damage to the heatsink/CPU as well.
Note Any physical damage to the CPU control card is not covered under
warranty.

Notice to user 2040PC/104CPUuser’smanual

iii
2040 PC/104 CPU user’s manual Contents
Contents
Abbreviations and terms used in this manual........................................... xiii
Conventions used in this manual .................................................................. xiv
Notes and warnings .......................................................................................xiv
Command format and procedures.................................................................xiv
About this manual
Overview: Section 1 – Installation
Chapter 1: Overview.................................................................................... 1-1
Description .................................................................................................... 1-1
2040 PC/104 CPU major hardware features............................................... 1-1
CPU....................................................................................................... 1-1
Solid–state disks .................................................................................. 1-1
SSD0 ............................................................................................ 1-1
SSD1 ............................................................................................ 1-1
SSD2 ............................................................................................ 1-1
RAM ...................................................................................................... 1-2
Serial ports protected against ESD..................................................... 1-2
Multifunctional printer port ................................................................ 1-2
Watchdog timer added for safety......................................................... 1-2
Real time calendar/clock with battery–backup .................................. 1-3
Keypad and LCD display support for low cost operator
interface .......................................................................................... 1-3
Speaker, keyboard, and mouse ............................................................ 1-3
PC/104 16–bit interface ....................................................................... 1-3
Hardware reset..................................................................................... 1-3
5 Volt operation lowers system cost .................................................... 1-3
2040 PC/104 CPU major software features ................................................ 1-4
Diagnostic software verifies system integrity automatically ............ 1-4
SETUP information stored in EEPROM for high reliability............. 1-4
Phoenix BIOS ....................................................................................... 1-4
Boot sequence ....................................................................................... 1-4
Fast boot ............................................................................................... 1-4
Specifications................................................................................................. 1-5
Rugged environmental operation........................................................ 1-5
Size........................................................................................................ 1-5
Chapter 2: Quick start ................................................................................ 2-1
Equipment required...................................................................................... 2-1
Configuration jumpers.................................................................................. 2-2
Installing the 2040 PC/104 CPU board....................................................... 2-4
Mounting on a flat surface................................................................... 2-4
Connecting to a PC/104 interface........................................................ 2-4
Power supply ................................................................................................. 2-5
Bootable disks ............................................................................................... 2-7
Serial console................................................................................................. 2-8
Floppy drive................................................................................................... 2-9

iv
Contents 2040 PC/104 CPU user’s manual
Configuring setup................................................................................. 2-9
Installing a floppy disk drive............................................................. 2-10
Creating a boot disk........................................................................... 2-11
Copying files................................................................................................ 2-11
Chapter 3: SETUP program ....................................................................... 3-1
Running SETUP over the console port ............................................... 3-4
SETUP example ................................................................................... 3-5
Chapter 4: Save and run programs.......................................................... 4-1
Save and run your programs on the 2040 PC/104 CPU............................. 4-1
Adding your application....................................................................... 4-1
Overriding the autoexecution of your application.............................. 4-2
Option 1 ....................................................................................... 4-2
Option 2 ....................................................................................... 4-2
Option 3 ....................................................................................... 4-2
Overview: Section 2 – Hardware
Chapter 5: Serial ports................................................................................ 5-1
Description .................................................................................................... 5-1
Serial port configurations............................................................................. 5-2
COM1.................................................................................................... 5-2
COM2.................................................................................................... 5-2
Function and use of serial ports................................................................... 5-3
COM1 as the serial console device ...................................................... 5-3
COM1 and COM2 as RS–232 I/O ....................................................... 5-4
Chapter 6: LPT1 parallel port ................................................................... 6-1
LPT1 parallel port ........................................................................................ 6-1
Printer ........................................................................................................... 6-1
Floppy drive................................................................................................... 6-2
Display........................................................................................................... 6-2
Keypad........................................................................................................... 6-3
Opto rack ....................................................................................................... 6-4
Chapter 7: Console devices ........................................................................ 7-1
Description .................................................................................................... 7-1
Selecting console devices .............................................................................. 7-1
COM1 as serial console device............................................................. 7-2
Keyboard, speaker, and mouse ............................................................ 7-4
Transferring files between the 2040 PC/104 CPU and your PC................ 7-5
ROM–DOS operating system .............................................................. 7-5
MS–DOS operating system ................................................................. 7-5
Transferring files to the 2040 PC/104 CPU ................................................ 7-6
Transferring files from the 2040 PC/104 CPU............................................ 7-7
Downloading files to the 2040 PC/104 CPU using PC SmartLINK .......... 7-8

v
2040 PC/104 CPU user’s manual Contents
Chapter 8: SSDs, DRAM, and battery backup ....................................... 8-1
Description .................................................................................................... 8-1
Booting........................................................................................................... 8-1
SSD0 .............................................................................................................. 8-1
SSD1 socket/M–Systems DiskOnChip......................................................... 8-1
SSD2 .............................................................................................................. 8-3
SSD2 socket.......................................................................................... 8-4
Accessing SRAM on the 2040 .............................................................. 8-4
DRAM ............................................................................................................ 8-6
Battery backup for SSD2 SRAM and real time calendar clock.................. 8-6
Chapter 9: External drives......................................................................... 9-1
Description .................................................................................................... 9-1
Floppy disk controller ................................................................................... 9-1
Power requirements ............................................................................. 9-1
Installing a floppy disk drive............................................................... 9-2
Hard disk controller ...................................................................................... 9-3
Chapter 10: Interpreting “beep” codes ................................................... 10-1
Description .................................................................................................. 10-1
Chapter 11: PC/104 expansion................................................................... 11-1
Description .................................................................................................. 11-1
Overview: Section 3 – System management
Chapter 12: Watchdog timer and hardware reset ................................ 12-1
Description .................................................................................................. 12-1
Watchdog function definitions using Borland C code................................ 12-1
Enable watchdog ................................................................................ 12-1
Strobe watchdog................................................................................. 12-1
Disable watchdog ............................................................................... 12-1
Watchdog function definitions using enhanced INT 17h handler............ 12-2
Enable watchdog ................................................................................ 12-2
Strobe watchdog................................................................................. 12-2
Disable watchdog ............................................................................... 12-3
Set WDTimer...................................................................................... 12-4
IncrementWDTimer........................................................................... 12-5
Hardware reset ........................................................................................... 12-6
Chapter 13: Serial EEPROM ...................................................................... 13-1
Description .................................................................................................. 13-1
Serial EEPROM .......................................................................................... 13-1
Read a single word from the serial EEPROM .................................. 13-1
Write a single word to the serial EEPROM...................................... 13-2
Read multiple words from the serial EEPROM ............................... 13-3
Write multiple words to the serial EEPROM ................................... 13-3
Return serial EEPROM size.............................................................. 13-4
Check CMOS battery ......................................................................... 13-5

vi
Contents 2040 PC/104 CPU user’s manual
Chapter 14: Troubleshooting..................................................................... 14-1
No screen activity – checking console serial communications......... 14-1
Garbled serial console screen activity............................................... 14-1
System generates a BIOS message but locks up when booting from
SSD1 ............................................................................................. 14-2
System will not recognize hard drive................................................ 14-2
System locks up after powerdown/powerup ..................................... 14-2
Technical assistance.................................................................................... 14-2
Overview: Section 4 – Appendices
Appendix A: Technical data ..........................................................................A-1
Technical specifications ................................................................................ A-1
Connector pinouts ......................................................................................... A-5
Appendix B: Software utilities .....................................................................B-1
Introduction................................................................................................... B-1
COM1CON.EXE............................................................................................B-2
I17HNDLR.EXE ........................................................................................... B-2
LPT1CON.COM ............................................................................................B-3
PGMBIOS.EXE .............................................................................................B-4
RESET.COM.................................................................................................. B-5
SETUP.COM .................................................................................................B-5
SCONSOLE.EXE .......................................................................................... B-7
Appendix C: Accessories ................................................................................C-1
Index
Warranty

vii
2040 PC/104 CPU user’s manual Contents
List of Figures
Figure 2–1 Component locations and mounting dimensions ................. 2-3
Figure 2–2 Power connector..................................................................... 2-6
Figure 2–3 M–Systems pin alignment with the 2040 SSD1 socket ...... 2-7
Figure 2–4 Serial console connections..................................................... 2-8
Figure 2–5 LPT1 and a Floppy Drive ................................................... 2-10
Figure 5–1 Custom null modem adapter with RTS and RI connected.. 5-3
Figure 5-2 2040 PC/104 CPU serial devices .......................................... 5-4
Figure 6–1 LPT1 as a printer port .......................................................... 6-1
Figure 6–2 LPT1 as a display or keypad port ........................................ 6-3
Figure 6–3 LPT1 and an opto rack.......................................................... 6-4
Figure 7–1 Custom null modem adapter with RTS and RI connected.. 7-2
Figure 7–2 The 2040 PC/104 CPU and a serial console ........................ 7-3
Figure 7–3 Downloading files using PC SmartLINK and
TRANSFER.EXE................................................................... 7-8
Figure 8–1 SSD socket locations ............................................................. 8-2
Figure 8–2 M–Systems pin alignment with the 2040 SSD1 socket ...... 8-2
Figure 9–1 LPT1 and a Floppy Drive ..................................................... 9-2
Figure 11–1 Typical PC/104 module stack ............................................. 11-1

viii
Contents 2040 PC/104 CPU user’s manual
List of Tables
Table 2–1 SETUP: W1........................................................................... 2-2
Table 2–2 Power pinout: J7................................................................... 2-6
Table 3-1 SETUP Jumpers: W1 ........................................................... 3-1
Table 5–1 COM1 and COM2 pinouts (J3 and J9 connectors).............. 5-2
Table 7–1 Speaker, battery, keyboard, and reset: J5 ........................... 7-4
Table 8–1 Connector J5 pinout .............................................................. 8-3
Table 8–2 System control register ......................................................... 8-5
Table 8–3 Speaker, battery, keyboard, and reset: J5 ........................... 8-6
Table 10–1 Phoenix BIOS beep codes.................................................... 10-2
Table 10–1 Phoenix BIOS beep codes (cont’d)....................................... 10-3
Table 10–2 Additional error codes for Phoenix BIOS ........................... 10-4
Table A–1 2040 PC/104 CPU memory map........................................... A-3
Table A–2 2040 PC/104 CPU I/O map...................................................A-3
Table A–3 DMA map...............................................................................A-4
Table A–4 Interrupt map........................................................................A-4
Table A–5 Available LPT1 port addresses.............................................A-4
Table A–6 PC/104 signal assignments...................................................A-5
Table A–7 Speaker, battery, keyboard, and reset: J5 ...........................A-6
Table A–8 Power: J7...............................................................................A-6
Table A–9 LPT1 printer connector: J4.................................................. A-7
Table C–1 Cables and terminal board ...................................................C-1
Table C–2 LCD displays and keypads ...................................................C-1
Table C–3 Opto rack and modules .........................................................C-2
Table C–4 Miscellaneous part numbers.................................................C-2

ix
2040PC/104CPUuser’smanual Abbreviations and terms used in this manual
Abbreviations and terms used in this
manual
Throughout this manual, the following symbols and terms are used:
Autoexecution Automatic execution of a program on powerup or
reset.
BIOS Basic Input Output System.
Console port Video card or COM1 where BIOS and DOS messages
appear and keyboard input is available.
DRAM Dynamic Random Access Memory devices.
Expansion card The expansion cards add I/O functions to the
PC/104 system, such as analog input/output, digital
input/output, motion control, and display.
Flash Electrically erasable PROM which allows at least
100,000 write cycles.
h The suffix “h” denotes a hexadecimal number. A
decimal number has no prefix or suffix. For example,
1000h and 4096 are equivalent.
KB Kilobyte (1,024 8–bit bytes).
MB Megabyte (1,048,576 8–bit bytes).
Memory device The type of static RAM, DRAM, flash memory, or
EPROM specified for either volatile or nonvolatile
memory.
PC/104 An expansion bus used for holding 8– and 16–bit
expansion expansion cards.
PC SmartLINK A serial communications software package designed
by Octagon for use with the 2040 PC/104 CPU.
Solid–state disk A simulated disk which uses a high speed solid–state
(SSD) memory device. For example, flash memory,
EEPROM, or static RAM.
SRAM Static Random Access Memory.
TTL compatible Transistor transistor logic compatible; 0–5V logic
levels.
W[ – ] Denotes a jumper block and the pins to connect.
XMODEM A communications protocol which allows transfer of
files between two computers.

x
Conventions used in this manual 2040PC/104CPUuser’smanual
Conventions used in this manual
≡Notes and warnings
Note A note is supplementary or background information. At other times,
it is a hint or reminder that makes a task easier or quicker.
WARNING!
A warning gives vital information. Failure to heed a warning may
cause system failure, equipment damage, or bodily harm to the
system operator.
≡ Command format and procedures
Commands must be entered in a specific format. To indicate the
format, this manual uses the conventions below. The conventions
cover the rules for issuing all commands, including the most complex
ones. The command format looks like this:
command [type_this |or_ this]
input { optional _ input }
Follow these rules and conventions:
nInformation which appears on your screen is shown in a different
type face, for example:
PhoenixBIOS(TM) A486 Version 1.03
Copyright (C) 1985-1994 Phoenix Technologies, Ltd.
All Rights Reserved
Octagon Systems Corp.
nCommands that you must key in are shown in Courier Bold, for
example:
C:> RESET
nItalicized refers to information that is specific to your particular
system or program, e.g.,
Enter
filename means enter the name of your file.
nPaired angle brackets are used to indicate a specific key on your
keyboard, e.g., <ESC> means the escape key; <CTRL> means the
control key; <F1> means the F1 function key.
nAll addresses are given in hexadecimal, for example, 328h.

2040PC/104CPUuser’smanual About this manual
About this manual
The 2040 PC/104 CPU user’s manual provides information about
installing and configuring the 2040 PC/104 CPU. This manual is
divided into four sections:
nSection 1 — Installation
Chapter 1: Overview
Chapter 2: Quick start
Chapter 3: SETUP programs
Chapter 4: Save and run programs
nSection 2 — Hardware
Chapter 5: Serial ports
Chapter 6: LPT1 parallel port
Chapter 7: Console devices
Chapter 8: SSDs, DRAM, and battery backup
Chapter 9: External drives
Chapter 10: Interpreting “beep” codes
Chapter 11: PC/104 expansion
nSection 3 — System management
Chapter 12: Watchdog timer and hardware reset
Chapter 13: Serial EEPROM
Chapter 14: Troubleshooting
nSection 4 — Appendices
Appendix A: Technical data
Appendix B: Software utilities
Appendix C: Accessories

About this manual 2040PC/104CPUuser’smanual

2040PC/104CPUuser’smanual Overview of Section 1
Overview: Section 1 – Installation
Section 1 provides installation and programming instructions, startup
options, and system configuration program examples. The following
chapters are included:
Chapter 1: Overview
Chapter 2: Quick start
Chapter 3: SETUP programs
Chapter 4: Save and run programs

Overview of Section 1 2040PC/104CPUuser’smanual

1–1
2040PC/104CPUuser’smanual Overview
Chapter 1: Overview
≡Description
The 2040 is a rugged and reliable PC/104 CPU with a low–power
386SX 40 MHz CPU. The 2040 PC/104 CPU integrates serial communi-
cations, a multifunctional parallel port, a solid–state disk, keyboard
and speaker ports, and a PC/104 interface.
≡2040 PC/104 CPU major hardware features
CPU
The CPU is a low–power 386SX with a clock speed of 40 MHz.
Solid–state disks
SSD0
The 2040 PC/104 CPU has an on–board 512 KB flash which contains
the BIOS and software extensions.
SSD1
A 32–pin DIP socket accepts an M–Systems DiskOnChip®. The socket
exhibits high retention force and affords a gas tight contact.
SSD2
A 32–pin DIP socket accepts either a 128 KB or a 512 KB SRAM.
SRAM is automatically backed up when an AT battery is connected.
The socket exhibits high retention force and affords a gas tight con-
tact.
RAM
The 2040 PC/104 CPU has 4 MB DRAM on board.

1–2
Overview 2040PC/104CPUuser’smanual
Serial ports protected against ESD
The 2040 PC/104 CPU has two serial ports for 8–wire RS–232C inter-
faces. COM1 can also be used as a console interface. These serial
ports have the following common specifications:
nIEC1000, level 3, ESD protection specification
— Contact discharge ±6 kV
— Air–gap discharge ±8 kV
nBackdrive protection
n16C550 compatible
nUp to 115.2K baud
n16–byte FIFO buffers
nEnabled and disabled in SETUP
Multifunctional printer port
The 2040 PC/104 CPU incorporates the latest enhanced parallel port.
It includes the following features:
nUnidirectional
nBidirectional
nIEEE 1284, ECP and EPP modes
n14 mA of drive current
nBackdrive protection
nFloppy drive mode
The following represent applications in the multifunctional parallel
port:
nLPT1 for PC compatible printers
n17 general purpose digital I/O lines
nUp to a 4 x 4 matrix keypad
n4–line alphanumeric display
nMPB–16PC, 16–position opto–module rack
Watchdog timer added for safety
The watchdog timer resets the system or generates an NMI
(nonmaskable interrupt) if the program stops unexpectedly. The
watchdog is enabled, disabled and strobed under software control.
The time–out period is 1.6 seconds typical, 1.00 seconds minimum to
2.25 seconds maximum. The watchdog timer can be strobed by the
I17HNDLR.EXE utility (a TSR program) to extend the timeout up to a
maximum of 60 hours.