Octagon 5266 User manual

5266 CPU card
Reference manual
Manual part #7739, rev. A07
CONTACT INFORMATION
Front Desk: 303–430–1500
Technical Support: 303–426–4521
[e-mail]
www.octagonsystems.com
1

Copyright
Micro PC™ is an Octagon Systems Corporation trademark, and Octagon
Systems Corporation®, and the Octagon logo are registered trademarks of Octagon
Systems Corporation. ROM–DOS™ is a trademark of Datalight. QNX® is a
registered trademark of QNX Software Systems Ltd. Windows 2000®, Windows
NT®, Windows XP® and Windows CE.net® are registered trademarks of Microsoft
Corporation. HyperTerminal ™ is a copyright of Hilgraeve, Inc. CompactFlash™ is
a trademark of San Disk Corporation. Ethernet® is a registered trademark of
Xerox Corporation.
Disclaimer
Copyright 2007—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.
Technical Support
Carefully recheck your system before calling Technical Support. Run as many tests
as possible; the more information you can provide, the easier it will be for Technical
Support staff to help you solve the problem. For additional technical assistance, try
the following:
Technical Support telephone: [phone]
E-mail Technical Support: [email protected]
Applications Notes (via web): www.octagonsystems.com
Revision History
Revision Reason for Change Date
A07 Initial Production Release 09 / 07
2

IMPORTANT!
Please read the following section before installing your product:
Octagon’s products are designed to be high in performance while consuming very
little power. In order to maintain this advantage, CMOS circuitry is used.
CMOS chips have specific needs and some special requirements that the user must
be aware of. Read the following to help avoid damage to your card from 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 exclusively using
CMOS technology. Both TTL and CMOS have failure mechanisms, but they are
different. Described below are some of the failures that are common to all
manufacturers of CMOS equipment.
The most common failures on CPU control 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.
Multiple component failures: The chance of a random component 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.
Testing “dead” cards: For a card that is “completely nonfunctional”, 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 ohmmeter 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.
Improper power causes catastrophic failure: If a card has had reverse
polarity or high voltage applied, replacing a failed component is not an
adequate fix. Other components probably have been partially damaged or a
failure mechanism has been induced. Therefore, a failure will probably occur in
the future. For such cards, Octagon highly recommends that these cards be
replaced.
Other over-voltage symptoms: In over-voltage situations, the
programmable logic devices, EPROMs and CPU chips, usually fail in this order.
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The failed device may be hot to the touch. It is usually the case that only one IC
will be overheated at a time.
Power sequencing: The major failure of I/O chips is caused by the external
application of input voltage while the power is off. If you apply 5V to the input
of a TTL chip with the power off, nothing 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.
Failure on power-up: 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 power-up. This type of failure is typical on
serial interface chips but can apply to any IC on the card.
Under-rated power supply: The board may fail to boot due to an under-
rated power supply. It is important that a quality power supply be used with
the 5266 that has sufficient current capacity, line and load regulation, hold up
time, current limiting, and minimum ripple. The power supply for the 5266
must meet the startup risetime requirements specified in the ATX Power
Design Guide, version 1.1, section 3.3.5. This assures that all the circuitry on
the CPU control card sequences properly and avoids system lockup.
Excessive 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 sub-microsecond 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 or 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 or CPU as well.
Note Any physical damage to the CPU card is not covered under warranty.
Excessive Thermal Stress
This card is guaranteed to operate over the published temperature ranges and
relevant conditions. However, sustained operation near the maximum temperature
specification is not recommended by Octagon or the CPU chip manufacturer due to
well known, thermal related, failure mechanisms. These failure mechanisms,
common to all silicon devices, can reduce the MTBF of the cards. Extended
operation at the lower limits of the temperature ranges has no limitations.
4

Table of Contents
Copyright ........................................................................................................................................................... 2
Disclaimer.......................................................................................................................................................... 2
Technical Support ............................................................................................................................................. 2
Revision History ................................................................................................................................................ 2
Using CMOS circuitry in industrial control ........................................................................................................ 3
Avoiding damage to the heatsink or CPU............................................................................................................ 4
Excessive Thermal Stress ................................................................................................................................. 4
Table of Contents .................................................................................................................................................. 5
List of Figures........................................................................................................................................................ 9
List of Tables........................................................................................................................................................ 10
Overview: Section 1 – Installation ................................................................................................................. 11
Chapter 1: Overview.......................................................................................................................................... 12
Description .......................................................................................................................................................... 12
5266 major hardware features ........................................................................................................................... 12
CPU.................................................................................................................................................................. 12
SDRAM ............................................................................................................................................................ 12
On-board flash ................................................................................................................................................. 12
CompactFlash socket ...................................................................................................................................... 12
Hard disk and IDE port .................................................................................................................................. 12
USB ports ........................................................................................................................................................ 13
Keyboard / mouse ............................................................................................................................................ 13
Digital I/O and LPT......................................................................................................................................... 13
Ethernet........................................................................................................................................................... 13
Serial ports protected against ESD ................................................................................................................ 13
Video ................................................................................................................................................................ 14
Audio................................................................................................................................................................ 14
Real time calendar/clock with battery backup............................................................................................... 14
Setup information stored in SEEPROM for high reliability ......................................................................... 14
User-available SEEPROM .............................................................................................................................. 14
Watchdog timer added for safety.................................................................................................................... 14
Hardware reset................................................................................................................................................ 14
5 Volt input power........................................................................................................................................... 15
Rugged environmental operation ................................................................................................................... 15
Size................................................................................................................................................................... 15
5266 major software features ............................................................................................................................. 16
Diagnostic software verifies system integrity automatically ........................................................................ 16
General Software BIOS................................................................................................................................... 16
Octagon built in INT 17 BIOS extensions...................................................................................................... 16
Boot sequence .................................................................................................................................................. 16
Chapter 2: Quick start ...................................................................................................................................... 17
Component diagrams, connectors, switches and cables.................................................................................... 17
5266 connectors and switches/jumpers .......................................................................................................... 22
Custom cables.................................................................................................................................................. 23
Mounting the 5266.............................................................................................................................................. 24
Using a Micro PC card cage ............................................................................................................................ 24
Panel mounting or stacking the 5266............................................................................................................. 26
Using the 5266 in a passive ISA backplane ................................................................................................... 29
5266 power supply requirements.................................................................................................................... 30
Installing an operating system........................................................................................................................... 31
OS on CD-ROM onto a hard drive or CompactFlash ........................................................................................ 31
Chapter 3: Setup programs.............................................................................................................................. 34
Setup.................................................................................................................................................................... 34
System BIOS Utility menu ............................................................................................................................. 35
Information Browser menu............................................................................................................................. 35
Basic CMOS Configuration menu .................................................................................................................. 36
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Features Configuration menu......................................................................................................................... 38
Custom Configuration menu........................................................................................................................... 40
Plug-n-Play Configuration menu.................................................................................................................... 42
Shadow/Cache Configuration menu ............................................................................................................... 42
Writing to CMOS and exiting ......................................................................................................................... 43
Overview: Section 2 – Hardware .................................................................................................................... 44
Chapter 4: Serial ports...................................................................................................................................... 45
Description .......................................................................................................................................................... 45
Mating receptacles .......................................................................................................................................... 45
Baud rate divisor registers ................................................................................................................................. 45
Serial port configurations................................................................................................................................... 46
Function and use of serial ports......................................................................................................................... 48
COM1 as serial console device........................................................................................................................ 48
COM1 and COM2 as RS–232 I/O ................................................................................................................... 48
COM2 as RS–422 or RS–485 networks .......................................................................................................... 48
RS–422............................................................................................................................................................. 49
RS–485............................................................................................................................................................. 50
Chapter 5: Console devices .............................................................................................................................. 51
Description .......................................................................................................................................................... 51
Selecting console devices .................................................................................................................................... 51
Monitor and keyboard console ........................................................................................................................ 51
Serial console................................................................................................................................................... 53
Hot key access to serial console ...................................................................................................................... 54
Chapter 6: CompactFlash, SDRAM, and battery backup........................................................................... 55
Description .......................................................................................................................................................... 55
CompactFlash ..................................................................................................................................................... 55
Setup configurations for CompactFlash......................................................................................................... 55
Creating a bootable CompactFlash ................................................................................................................ 56
SDRAM................................................................................................................................................................ 56
Battery backup for real time calendar clock...................................................................................................... 57
Installing an AT battery ................................................................................................................................. 57
Chapter 7: External drives............................................................................................................................... 58
Description .......................................................................................................................................................... 58
Setup configurations for hard drives ................................................................................................................. 58
Hard disk controller............................................................................................................................................ 58
Master/slave designation for IDE devices ...................................................................................................... 58
Installing a hard drive........................................................................................................................................ 60
Chapter 8: Bit-programmable digital I/O...................................................................................................... 61
Description .......................................................................................................................................................... 61
BIOS Setup configuration for digital I/O ........................................................................................................... 61
Interfacing to switches and other devices.......................................................................................................... 64
Opto-module rack interface ............................................................................................................................ 64
Organization of banks......................................................................................................................................... 66
Port addressing................................................................................................................................................ 66
19 I/O lines configurable for pulled low / pulled high.................................................................................... 67
Configuring and programming the I/O port ...................................................................................................... 67
Programming the I/O ...................................................................................................................................... 67
Configuring the I/O ......................................................................................................................................... 67
Writing and reading from I/O ......................................................................................................................... 68
I/O output program examples......................................................................................................................... 69
I/O input program examples ........................................................................................................................... 69
Built-in BIOS function definitions ..................................................................................................................... 70
Initialize I/O .................................................................................................................................................... 70
Write I/O .......................................................................................................................................................... 70
Read I/O ........................................................................................................................................................... 71
Chapter 9: LPT1 parallel port ......................................................................................................................... 72
BIOS Setup configuration for LPT1................................................................................................................... 72
Configuring the LPT signals .............................................................................................................................. 72
Creating a printer cable...................................................................................................................................... 73
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Installing a printer ............................................................................................................................................. 74
Chapter 10: CRTs and TFT flat panels .......................................................................................................... 75
Description .......................................................................................................................................................... 75
Video features ..................................................................................................................................................... 75
Connecting a monitor.......................................................................................................................................... 75
Connecting a flat panel display.......................................................................................................................... 77
BIOS Setup for flat panels .............................................................................................................................. 77
Flat panels requiring bias voltage.................................................................................................................. 77
5V flat panels................................................................................................................................................... 77
Connecting the flat panel to the 5266 ............................................................................................................ 78
Chapter 11: Ethernet......................................................................................................................................... 80
Description .......................................................................................................................................................... 80
Chapter 12: USB ................................................................................................................................................. 81
Description .......................................................................................................................................................... 81
USB hard drives and CD-ROMs ........................................................................................................................ 81
Chapter 13: Audio and PC beep speaker ...................................................................................................... 82
Description .......................................................................................................................................................... 82
Overview: Section 3 – System management................................................................................................. 83
Chapter 14: Watchdog timer and hardware reset ...................................................................................... 84
Description .......................................................................................................................................................... 84
Booting, power down, and strobing the watchdog timer ............................................................................... 84
Watchdog function definitions using enhanced INT 17h handler ....................................................................85
Enable watchdog ............................................................................................................................................. 85
Strobe watchdog .............................................................................................................................................. 85
Disable watchdog............................................................................................................................................. 86
Hardware reset ................................................................................................................................................... 86
Chapter 15: Serial EEPROM............................................................................................................................ 87
Description .......................................................................................................................................................... 87
Built-in INT 17h function definitions ................................................................................................................ 87
Serial EEPROM .................................................................................................................................................. 87
Read a single byte from the serial EEPROM................................................................................................. 87
Write a single byte to the serial EEPROM .................................................................................................... 87
Return serial EEPROM size ...........................................................................................................................88
Chapter 16: System switches, user switches, BIOS update and LEDs................................................... 90
System switches.................................................................................................................................................. 90
System switch.................................................................................................................................................. 90
Video switch..................................................................................................................................................... 90
User switch ...................................................................................................................................................... 90
INT17 calls to read user switches ...................................................................................................................... 91
BIOS programming using REFLASH.EXE ....................................................................................................... 92
LEDs.................................................................................................................................................................... 92
Chapter 17: CPU clock and ISA bus interrupt routing ............................................................................. 93
CPU clock speed.................................................................................................................................................. 93
ISA bus and onboard interrupt routing ............................................................................................................. 93
Chapter 18: Troubleshooting........................................................................................................................... 95
No system LED activity...................................................................................................................................... 95
No CRT or flat panel video ................................................................................................................................. 95
Video is present but is distorted......................................................................................................................... 96
No serial console activity .................................................................................................................................... 96
Garbled serial console screen activity................................................................................................................ 96
System generates a BIOS message but locks up when booting........................................................................ 97
System will not boot from CompactFlash .......................................................................................................... 97
System locks up on power-up; may or may not respond to reset switch .......................................................... 97
System locks up after power-down/power-up .................................................................................................... 97
LED signaling of “beep” counts .......................................................................................................................... 97
Technical assistance ......................................................................................................................................... 102
Overview: Section 4 – Appendices................................................................................................................ 103
Appendix A: 5266 technical data .................................................................................................................. 104
Technical specifications .................................................................................................................................... 104
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CPU................................................................................................................................................................ 104
Front Side Bus............................................................................................................................................... 104
PCI and LPC bus clock.................................................................................................................................. 104
ISA bus clock ................................................................................................................................................. 104
BIOS............................................................................................................................................................... 104
SDRAM .......................................................................................................................................................... 104
On-board flash ............................................................................................................................................... 104
Hard drive...................................................................................................................................................... 104
CompactFlash socket .................................................................................................................................... 104
USB................................................................................................................................................................ 104
Serial I/O........................................................................................................................................................ 104
Digital I/O ...................................................................................................................................................... 104
LPT................................................................................................................................................................. 104
Keyboard and mouse ports............................................................................................................................ 104
Ethernet......................................................................................................................................................... 105
Video .............................................................................................................................................................. 105
Audio.............................................................................................................................................................. 105
Watchdog timer ............................................................................................................................................. 105
Real time clock............................................................................................................................................... 105
Operating systems......................................................................................................................................... 105
Power requirements ...................................................................................................................................... 105
Environmental specifications ....................................................................................................................... 105
Size................................................................................................................................................................. 105
Weight............................................................................................................................................................ 105
Excessive Thermal Stress ............................................................................................................................. 105
Mating connectors............................................................................................................................................. 106
Maps .................................................................................................................................................................. 107
Switch settings.................................................................................................................................................. 109
Jumper Settings................................................................................................................................................ 110
Connector pin–outs ........................................................................................................................................... 111
Appendix B: Software utilities...................................................................................................................... 118
Introduction....................................................................................................................................................... 118
Support commands........................................................................................................................................ 118
REFLASH.EXE................................................................................................................................................. 119
RESET.COM ..................................................................................................................................................... 119
Appendix C: Accessories.................................................................................................................................. 120
Warranty ............................................................................................................................................................. 121
Limitations on warranty................................................................................................................................... 121
Service policy..................................................................................................................................................... 121
Returning a product for repair ......................................................................................................................... 121
Returns.............................................................................................................................................................. 122
Governing law ................................................................................................................................................... 122
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List of Figures
Figure 2–1 5266 component diagram (top) ........................................................................................18
Figure 2–2 5266 component diagram (bottom)..................................................................................19
Figure 2–3 5266 dimensions (inches).................................................................................................20
Figure 2–4 5266 dimensions (mm).....................................................................................................21
Figure 2–5 5266, VGA monitor, and USB keyboard .........................................................................25
Figure 2–6 Edge connector orientation..............................................................................................25
Figure 2–7 Populated Micro PC card cage.........................................................................................26
Figure 2–8 Panel mounting the 5266.................................................................................................27
Figure 2–9 Stacking the 5266 ............................................................................................................27
Figure 2–10 Power connector: J11 diagram ........................................................................................28
Figure 2–11 5266, VGA monitor, USB keyboard, and power supply .................................................28
Figure 2–12 Using a passive ISA backplane .......................................................................................30
Figure 2–13 Installing an operating system........................................................................................33
Figure 4–1 COM ports ........................................................................................................................46
Figure 4–2 VTC-20F cable and null modem adapter ........................................................................47
Figure 4–3 Typical RS–422 four-wire interface circuit.....................................................................49
Figure 4–4 Typical RS–485 two–wire half duplex interface circuit .................................................50
Figure 5–1 Monitor and keyboard as console ....................................................................................52
Figure 5–2 The 5266 and a serial console..........................................................................................54
Figure 7–1 5266 with IDE devices .....................................................................................................59
Figure 8–1 Typical digital I/O configuration .....................................................................................63
Figure 8–2 Organization of banks......................................................................................................66
Figure 9–1 Custom printer cable .......................................................................................................73
Figure 10–1 The 5266 and a VGA monitor..........................................................................................76
Figure 10–2 The 5266 and a flat panel display ...................................................................................78
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List of Tables
Table 2–1 5266 connector functions .................................................................................................22
Table 2–2 5266 switch/jumper functions .........................................................................................22
Table 4–1 Baud rate divisors............................................................................................................45
Table 4–2 COM1 and COM2 connector pin-outs (J4 connector) .....................................................47
Table 4–3 COM2 termination switch, Switch 2...............................................................................47
Table 6–1 CompactFlash, UDMA, RS485 termination switch, SW2..............................................55
Table 6–2 Battery connector.............................................................................................................57
Table 8–1 J7 arranged by function – digital I/O connector.............................................................62
Table 8–2 J7 arranged by pins – digital I/O connector....................................................................62
Table 8–3 Digital I/O opto-rack interface ........................................................................................65
Table 8–4 Digital I/O pulled high / pulled low jumper ....................................................................67
Table 8–5 I/O port byte .....................................................................................................................68
Table 9–1 LPT lines pulled low jumper ...........................................................................................72
Table 9–1 DB-25 routing to J7 connector.........................................................................................74
Table 10–1 J6 – CRT connector..........................................................................................................76
Table 10–2 J501 – flat panel connector..............................................................................................79
Table 11–1 Ethernet LEDs .................................................................................................................80
Table 13–1 J9 – audio connector ........................................................................................................82
Table 13–2 W2 – PC speaker connector .............................................................................................82
Table 16−1System configuration switches, Switch 500....................................................................90
Table 17–1 ISA bus interrupt routing................................................................................................94
Table 17–2 Onboard interrupt routing ..............................................................................................94
Table 18–1 POST port 80 codes..........................................................................................................98
Table 18–2 BIOS beep counts...........................................................................................................101
Table A–1 5266 mating connectors .................................................................................................106
Table A–2 5266 I/O map..................................................................................................................107
Table A–3 5266 interrupt map........................................................................................................108
Table A–4 5266 memory map..........................................................................................................108
Table A–5 CompactFlash, UDMA, RS485 termination switch, Switch2 ......................................109
Table A–6 System configuration switches, Switch 500..................................................................109
Table A–7 Digital I/O pulled high / pulled low jumper, W1...........................................................110
Table A–8 ISA bus interrupt routing, W4 and W5.........................................................................110
Table A–9 Onboard interrupt routing, W4 .....................................................................................110
Table A–10 W2– PC Speaker connector ..........................................................................................111
Table A–11 J1 – Dual USB connector...............................................................................................111
Table A–12 J2 – Ethernet connector.................................................................................................111
Table A–13 J3 – Battery connector...................................................................................................111
Table A–14 J4 – COM1 and COM2 connector..................................................................................111
Table A–15 J4 – COM2 connector.....................................................................................................112
Table A–16 J5 – USB3/4 connector...................................................................................................112
Table A–17 J6 – CRT connector........................................................................................................112
Table A–18 J7 – Digital I/O connector..............................................................................................113
Table A–19 J7 – LPT connector ........................................................................................................113
Table A–20 J8 – EIDE connector ......................................................................................................114
Table A–21 J9 – Audio connector......................................................................................................114
Table A–22 J10 – ISA bus connector ................................................................................................115
Table A–23 J11 – Power connector ...................................................................................................115
Table A–24 J500 – CompactFlash ....................................................................................................116
Table A–25 J501 – flat panel connector............................................................................................117
Table C–1 Cables and accessories...................................................................................................120
Table C–2 Digital I/O accessories ...................................................................................................120
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