Octagon PC-600 User manual

PC–600 Single Board Computer
Reference manual
Manual part #6437, rev. 0806
CONTACT INFORMATION
Front Desk: 303–430–1500
Technical Support: 303–426–4521
[e-mail]
www.octagonsystems.com

Copyright
OS Embedder™ is a 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 2003, 2004, 2005, 2006—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

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 which are common to all manufacturers of CMOS equipment.
The most common failures on Single Board Computers 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.
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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. 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 Micro PC 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 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 PC–600 SBC that has sufficient current capacity, line
and load regulation, hold up time, current limiting, and minimum
ripple. The power supply for the PC–600 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 switch 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.
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Avoiding damage to the heatsink or CPU
WARNING!
When handling any Octagon Single Board Computer,
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 Single Board Computer, since this
may cause damage to the heatsink or CPU as well.
Note Any physical damage to the CPU control 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.
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Table of Contents
Copyright.......................................................................................................................... 2
Disclaimer ........................................................................................................................ 2
Technical Support............................................................................................................ 2
Using CMOS circuitry in industrial control......................................................................3
Avoiding damage to the heatsink or CPU .........................................................................5
Excessive Thermal Stress ...............................................................................................5
Table of Contents ...............................................................................................................6
List of Figures...................................................................................................................12
List of Tables .....................................................................................................................13
Overview: Section 1 – Installation ..............................................................................15
Chapter 1: Overview.......................................................................................................16
Description ........................................................................................................................16
PC–600 major hardware features....................................................................................16
CPU ................................................................................................................................16
SDRAM........................................................................................................................... 16
On-board flash ............................................................................................................... 16
Hard disk, CompactFlash, and floppy disk ports......................................................... 17
USB ports ....................................................................................................................... 17
Serial ports..................................................................................................................... 17
Digital I/O ...................................................................................................................... 17
Speaker, keyboard, and mouse ports............................................................................ 17
Video............................................................................................................................... 18
PC/104 and PC/104 Plus interface................................................................................ 18
Ethernet ......................................................................................................................... 18
Multifunctional printer port ......................................................................................... 18
Watchdog timer added for safety .................................................................................. 18
Real time calendar/clock with battery–backup............................................................ 18
Setup information stored in EEPROM for high reliability ......................................... 19
Hardware reset .............................................................................................................. 19
Temperature sensor....................................................................................................... 19
5 volt operation lowers system cost .............................................................................. 19
Rugged environmental operation.................................................................................. 20
Size ................................................................................................................................. 20
PC–600 major software features......................................................................................21
Diagnostic software verifies system integrity automatically ...................................... 21
Phoenix BIOS................................................................................................................. 21
Octagon BIOS extensions.............................................................................................. 21
Boot sequence................................................................................................................. 21
Chapter 2: Quick start ...................................................................................................22
Hardware installation ......................................................................................................22
Installing the PC–600.......................................................................................................27
Installation..................................................................................................................... 27
Hardware mounting ...................................................................................................... 28
Power connection ........................................................................................................... 29
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Monitor........................................................................................................................... 30
Keyboard and mouse ..................................................................................................... 30
Speaker........................................................................................................................... 30
Installing an operating system ........................................................................................30
OS on floppy onto a hard drive or CompactFlash ........................................................ 31
OS on CD-ROM onto a hard drive or CompactFlash................................................... 32
Power supply requirements .............................................................................................34
Power supply requirements .............................................................................................35
Chapter 3: Setup programs...........................................................................................36
Operating systems other than DOS.................................................................................36
Setup .................................................................................................................................36
Main menu ..................................................................................................................... 37
Hard drive submenus .................................................................................................... 38
Advanced menu.............................................................................................................. 39
Advanced Chipset Control submenu ............................................................................ 40
I/O Device Configuration submenu .............................................................................. 41
Audio Options submenu ................................................................................................ 42
PCI Configuration submenu ......................................................................................... 43
PCI Configuration submenu ......................................................................................... 43
PCI/PNP ISA UMB Region Exclusion submenu .......................................................... 44
PCI/PNP ISA IRQ Resource Exclusion submenu ........................................................ 45
PCI/PNP ISA DMA Resource Exclusion submenu ...................................................... 45
Power menu ................................................................................................................... 46
Boot menu ...................................................................................................................... 47
Expanded Boot screen ................................................................................................... 47
Exit menu....................................................................................................................... 48
Chapter 4: Save and run programs.............................................................................49
Save and run your programs on the PC–600 ..................................................................49
Saving programs and support files..................................................................................49
Adding your application ................................................................................................ 49
Overriding the autoexecution of your application ....................................................... 50
Option 1.......................................................................................................................... 50
Option 2.......................................................................................................................... 50
Option 3.......................................................................................................................... 50
Option 4.......................................................................................................................... 50
Overview: Section 2 – Hardware .................................................................................51
Chapter 5: Serial ports...................................................................................................52
Description ........................................................................................................................52
Serial port configurations.................................................................................................53
Serial port configurations.................................................................................................54
Function and use of serial ports.......................................................................................56
COM1 as serial console device ...................................................................................... 56
Mating receptacle .......................................................................................................... 56
COM Ports as RS–232 I/O............................................................................................. 57
COM3 and COM4 as RS–422 and RS–485 networks .................................................. 57
RS–422 ........................................................................................................................... 58
RS–485 ........................................................................................................................... 58
Chapter 6: LPT1 parallel port, LCD and keypad.....................................................60
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LPT1 parallel port ............................................................................................................60
Installing a printer ...........................................................................................................60
Display ..............................................................................................................................61
Installing a display ........................................................................................................ 61
Keypad...............................................................................................................................62
Installing a keypad ........................................................................................................ 63
Chapter 7: Console devices ...........................................................................................64
Description ........................................................................................................................64
Selecting console devices ..................................................................................................64
Monitor and keyboard console ...................................................................................... 64
Serial console ................................................................................................................. 65
Chapter 8: CompactFlash, SDRAM, and battery backup........................................68
Description ........................................................................................................................68
CompactFlash ...................................................................................................................68
Creating a bootable CompactFlash............................................................................... 69
SDRAM..............................................................................................................................69
Battery backup for real time calendar clock ...................................................................70
Installing an AT battery................................................................................................ 70
Chapter 9: External drives............................................................................................71
Description ........................................................................................................................71
Floppy disk controller.......................................................................................................71
Power requirements ...................................................................................................... 71
Installing a floppy disk drive ........................................................................................ 71
Hard disk controller .........................................................................................................72
Master/slave designation for IDE devices .................................................................... 72
Installing a hard drive................................................................................................... 72
Chapter 10: Bit-programmable digital I/O ................................................................74
Description ........................................................................................................................74
Interfacing to switches and other devices .......................................................................75
Opto-module rack interface........................................................................................... 75
Organization of banks ......................................................................................................78
Port addressing .............................................................................................................. 78
Base I/O address ............................................................................................................ 79
Pulling the I/O lines high or low......................................................................................79
Configuring and programming the digital I/O ports ......................................................80
Programming the I/O..................................................................................................... 80
Configuring the I/O........................................................................................................ 80
Writing and reading from I/O ....................................................................................... 81
Digital I/O output program examples........................................................................... 82
Digital I/O input program examples............................................................................. 82
Enhanced INT 17h function definitions ..........................................................................83
Initialize I/O................................................................................................................... 83
Write I/O......................................................................................................................... 83
Read I/O.......................................................................................................................... 84
Chapter 11: CRTs and flat panels................................................................................86
Video features ...................................................................................................................86
Connecting a monitor .......................................................................................................87
Connecting a flat panel display .......................................................................................89
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Flat panels requiring bias voltage ................................................................................ 89
Connecting the flat panel to the PC–600 ..................................................................... 91
Programming the video BIOS ..........................................................................................93
Additional notes on video BIOS .................................................................................... 93
Chapter 12: Ethernet......................................................................................................94
Description ........................................................................................................................94
Chapter 13: USB ..............................................................................................................95
Description ........................................................................................................................95
Chapter 14: Audio ...........................................................................................................96
Description ........................................................................................................................96
Chapter 15: PC/104 and PC/104 Plus expansion.......................................................98
Description ........................................................................................................................98
Overview: Section 3 – System management............................................................100
Chapter 16: Watchdog timer and hardware reset .................................................101
Description ......................................................................................................................101
Timeout period (ranges) .............................................................................................. 101
Booting, power down, and strobing the watchdog timer ........................................... 101
Watchdog function definitions using enhanced INT 17h handler ...............................102
Enable watchdog.......................................................................................................... 102
Strobe watchdog........................................................................................................... 102
Disable watchdog......................................................................................................... 103
Hardware reset ...............................................................................................................104
Chapter 17: Serial EEPROM.......................................................................................105
Description ......................................................................................................................105
Enhanced INT 17h function definitions ........................................................................105
Serial EEPROM..............................................................................................................105
Read a single word from the serial EEPROM............................................................ 105
Write a single word to the serial EEPROM ............................................................... 106
Read multiple words from the serial EEPROM......................................................... 106
Write multiple words to the serial EEPROM............................................................. 107
Return serial EEPROM size .......................................................................................108
Chapter 18: Temperature sensor and user jumper...............................................109
Description ......................................................................................................................109
Temperature sensor INT17h function definitions ........................................................109
Write TEMP SENSOR register pointer...................................................................... 109
Read TEMP SENSOR current register ...................................................................... 110
Write TEMP SENSOR current register ..................................................................... 111
Read TEMP SENSOR Int Status bit .......................................................................... 111
Read user jumper............................................................................................................112
Chapter 19: CPU clock, system jumpers, and BIOS recovery.............................113
Description ......................................................................................................................113
System jumper ............................................................................................................. 114
Extended BIOS jumper ............................................................................................... 114
Video jumper................................................................................................................ 114
User jumper ................................................................................................................. 115
BIOS recovery jumper ................................................................................................. 115
BIOS programming using PHLASH.EXE .................................................................. 116
Chapter 20: Troubleshooting......................................................................................117
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Boot Block Recovery .......................................................................................................117
Memory conflicts using operating system other than DOS..........................................117
No system LED activity .................................................................................................117
No CRT or flat panel video.............................................................................................118
Video is present but is distorted ....................................................................................118
No serial console activity................................................................................................119
Garbled console screen activity......................................................................................119
System generates a BIOS message but locks up when booting ...................................120
System will not boot from CompactFlash .....................................................................120
System locks up on power–up; may or may not respond to reset switch.....................120
System locks up after power–down/power–up ..............................................................121
LED signaling of “beep” codes........................................................................................121
Description ................................................................................................................... 121
Technical assistance .......................................................................................................124
Overview: Section 4 – Appendices.............................................................................125
Appendix A: PC–600 technical data ..........................................................................126
Technical specifications..................................................................................................126
CPU .............................................................................................................................. 126
Bus clock....................................................................................................................... 126
BIOS ............................................................................................................................. 126
SDRAM......................................................................................................................... 126
On-board flash ............................................................................................................. 126
Hard drive .................................................................................................................... 126
CompactFlash socket................................................................................................... 126
Floppy drive ................................................................................................................. 126
USB .............................................................................................................................. 126
Serial I/O ...................................................................................................................... 127
Parallel port ................................................................................................................. 127
Digital I/O .................................................................................................................... 127
Speaker, Keyboard, and Mouse ports ......................................................................... 127
Video............................................................................................................................. 127
Ethernet ....................................................................................................................... 127
Watchdog timer............................................................................................................ 127
Real time clock............................................................................................................. 127
Expansion..................................................................................................................... 127
Operating systems ....................................................................................................... 127
PCI bus mastering ....................................................................................................... 128
Power requirements .................................................................................................... 128
Environmental specifications...................................................................................... 128
Size ............................................................................................................................... 128
Weight .......................................................................................................................... 128
Excessive Thermal Stress ...........................................................................................128
Mating connectors ..........................................................................................................129
Maps ................................................................................................................................130
Jumper settings ..............................................................................................................132
Connector pin-outs..........................................................................................................135
Appendix B: Software utilities...................................................................................145
Introduction ....................................................................................................................145
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