RadiSys 6200plus Series User manual

Service Manual
© 1999 RadiSys Corporation
All Rights Reserved
Printed in USA
6200plus Series Chassis
30901-002
December 1999

i6200
plus Series Service Manual
Limited Warranty
A. RadiSys Corporation warrants that the item sold by it hereunder will be free from defects in materials or
workmanship, under normal use and service, for a period of 2 years from date of shipment. Said item
will meet the specifications in effect at the time of manufacture. RadiSys’ sole obligation under this
warranty shall be, at its option, to repair or replace, without charge, any defective component of said
item, within a reasonable period of time.
B. RadiSys Corporation shall not be liable under this warranty for (i) the item that the Buyer alleges to be
defective and was repaired or altered by someone other than RadiSys designated personnel or authorized
representative, unless such repair or alteration was effected pursuant to prior written approval of
RadiSys, or (ii) where the Buyer fails to notify RadiSys of any alleged defect within the period of
warranty, or (iii) where the Buyer fails to return the allegedly defective item to RadiSys, in Houston,
Texas, USA, freight prepaid, or (iv) where the item was altered or damaged in a way which RadiSys
reasonably determines to affect the performance and reliability of the item, or (v) where the item was
subject to misuse, neglect, or accident. The rights and remedies granted to the Buyer under this
paragraph constitute the Buyer’s sole and exclusive remedy against RadiSys Corporation, its officers,
agents, and employees, for negligence, inexcusable delay, breach of warranty, express or implied, or any
other default relating to the item or RadiSys’ duties to eliminate any errors.
This warranty supersedes any other warranty, whether expressed, implied, or statutory, including but not
limited to any warranty for fitness of purpose, merchantability, or freedom from infringement or the like, and
any warranty otherwise arising out of any proposal, specifications, or sample. Furthermore, RadiSys
Corporation neither assumes nor authorizes any person to assume for it any other liability.
The software included with this equipment is warranted only in accordance with the terms of its license
agreement. Except as warranted in that license agreement, the manufacturer of the software disclaims all
warranties and conditions with regard to the software, including all implied warranties and conditions of
merchantability, fitness for a particular purpose, title, and non-infringement.
Every effort has been made to ensure that the information provided in this manual is complete and accurate.
However, technical inaccuracies or typographical errors may be inadvertently included. RadiSys assumes no
responsibility for any errors that may be contained in this document. RadiSys makes no promise to update or
keep current the information contained in this document. Information in this document, including product
specifications, is subject to change without notice.
Any rights not expressly granted herein are reserved.
All tradenames referenced are the service mark, trademark, or registered trademark of the respective manufacturer.

Service Manual 6200plus Series ii
Important
Always use caution when handling or operating the equipment. Only qualified and trained electronics
service personnel should access the equipment. Use extreme caution when installing or removing
components. For additional information, please contact RadiSys Technical Support at [phone] or
[phone] Monday through Friday between 7:00 a.m. and 6:00 p.m., Central Time, Continental USA.
Wichtig
Arbeiten am System bzw. Betrieb des Systems, sollten immer mit der nötigen Vorsicht vorgenommen
werden. Nur qualifiziertes und ausgebildetes Fachpersonal sollte am Inneren des Gerätes arbeiten. Beim
Installieren und Entfernen von Komponenten ist besondere Vorsicht geboten.
Für weitere Informationen wenden Sie sich bitte an den Technical Support von RadiSys:
•USA:[phone] oder [phone] Montags bis Freitags von 0700 Uhr bis 1800 Uhr, Central USA.
•International:[phone] Montags bis Freitags von 0830 Uhr bis 1700 Uhr. (CET GMT +1.00)
Changes or modifications not expressly approved by RadiSys Corporation could
void the product warranty and the user's authority to operate the equipment.

iii 6200plus Series Service Manual
Notice
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can emit radio frequency energy and, if not installed and used in
accordance with this instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference, in which case, the
user will be required to correct the interference at the user's expense.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following conditions:
•This device may not cause harmful interference
•This device must accept any interference received, including interference that may cause undesired
operation
Any change or modification not expressly approved by the manufacturer is prohibited and could void the
user's authority to operate the equipment.

Service Manual 6200plus Series iv
Document Conventions
Typography Title Case Titles of menus, windows, tabs, lists, and groups.
Bold Title Case Names of menu items, fields, buttons, icons, check boxes, list
items, group items, and keystrokes.
UPPER CASE Acronyms and abbreviations.
Italics Emphasis.
Sans Serif Type Items in tables, illustrations, and notations.
Monospace Type Output from a printer or monitor. Graphic items will be
displayed as an image.
Symbols Notice:
This symbol indicates an item for special consideration.
Warning:
This symbol indicates the presence of a potential hazard that can
cause personal injury. Only qualified and trained electronics
service personnel should access the equipment.

v6200
plus Series Service Manual
Customer Support
Calling
Technical
Support
Step Action
1Have the RadiSys product model and serial number available.
2•In the Continental USA, Monday — Friday, 7:00 a.m. — 6:00 p.m., Central Time, dial
1-800-438-4769 in the USA. Outside the USA, dial 713-541-8200 (add long distance/
international access codes).
•In Europe, Monday — Friday, 8:30 a.m. — 5:00 p.m., dial [phone].
Returning
Productsfor
Service
Step Action
1Have the RadiSys product model and serial number available.
2•In the Continental USA, Monday — Friday, 7:00 a.m. — 6:00 p.m., Central Time, dial
1-800-438-4769 in the USA. Outside the USA, dial 713-541-8200 (add long distance/
international access codes).
•In Europe, Monday — Friday, 8:30 a.m. — 5:00 p.m., dial [phone].
3When you are assigned a Returned Goods Authorization (RGA) number from a
Technical Support Representative, place it, along with the product serial number, on the
packaging materials and correspondence. The factory will be unable to accept delivery
without these numbers.
Note: The factory does not accept RGA's sent freight collect.
Accessing
the Website http://www.radisys.com
Upon receiving your equipment, inspect the packaging, shipping materials, and contents.
If damaged, return the equipment to RadiSys in the original packaging and shipping materials.
If you are satisfied with your equipment, retain the packaging and shipping materials in case of
future need.

Service Manual 6200plus Series vi
Table of Contents
Chapter 1 Operations 1
User-Accessible Features .................................................................................2
Specifications ....................................................................................................5
Chapter 2 Service 7
Accessing the Interior........................................................................................8
Internal Features .............................................................................................10
Expansion Cards.............................................................................................12
Drives and Media.............................................................................................16
Fan Tray ..........................................................................................................21
Air Filter...........................................................................................................24
Power Supply ..................................................................................................26
Model Components .........................................................................................28

vii 6200plus Series Service Manual
List of Figures
1 Front Features ....................................................................................................................3
2 Rear Features.....................................................................................................................4
3 Dimensions.........................................................................................................................6
4 Removing the Top Cover ....................................................................................................9
5 Internal Features...............................................................................................................11
6 Expansion Card Guide Bracket ........................................................................................13
7 Expansion Card Guides....................................................................................................13
8 Expansion Card Retention Bracket...................................................................................14
9 Installing the Expansion Card Retention Bracket .............................................................15
10 Removing the Media Drawer ............................................................................................17
11 Removing the 3½” Drive Bay............................................................................................19
12 Installing Drives ................................................................................................................20
13 Installing the Fan Tray ......................................................................................................22
14 Fan Tray Interconnect Board............................................................................................23
15 Connecting the Fans.........................................................................................................23
16 Air Filter Installation..........................................................................................................25
17 Power Supply Indicators and Controls..............................................................................27
18 Mounting Holes for Model Components ...........................................................................28
19 Installing the Rack-Mount Components............................................................................29
20 Installing the Tower Components......................................................................................30
21 Installing the Tower Foot...................................................................................................31
22 Removing the Tower Cover ..............................................................................................31

Service Manual 6200plus Series 1
Operations
This chapter discusses the primary features of the 6200plus series chassis.
If you are familiar with the primary components and functions of the 6200plus, go
to Chapter 2, “Service,” page 7. Then read this chapter later at your convenience.
1
This chapter discusses functions and features of the equipment that
can be accessed by all users, regardless of training or skill level. The
material contained in this chapter discusses only user-accessible parts
and/or operations.

Operations
26200
plus Series Service Manual
User-Accessible Features
Overview The 6200plus series chassis provides features that permit great flexibility. This chassis
presents a highly configurable solution with exceptional performance.
Models The 6200plus is available in three (3) mounting systems:
•Benchtop
•Rack-mount
•Tower
For more information on model components, see page 28.
Front Access The following features are accessible from the front of the chassis (Figure 1):
•System reset button
•System power LED (green)
•Drive activity LED (amber)
Note: Dual reset buttons and LED’s are provided for a split backplane system.
•System power ON/OFF switch
•Cooling fan air filter
•Removable media accessible from the front panel:
•Four (4) 5¼” x 1.72” drives
•One (1) 3½” x 1” drive, typically a floppy disk drive
•Internal drives:
•Two (2) 3½” x 1” drives, or
•One (1) 3½” x 1.6” drive
Rear Access The following features are accessible from the rear of the chassis (Figure 2):
•Twenty (20) expansion slots
•AT-style keyboard connector
Note: Dual connectors are provided for a split backplane system.
•Parallel and serial port access
Note:Dual access is provided for a split backplane system.
•Power supply area
Note: For more information, see page 26.
Power Supply The power supply alarm features function only with the hot-swappable power supply
option. For more information, see page 26.

Operations
Service Manual 6200plus Series 3
Figure 1 Front Features
Note: This illustration shows components for dual hot-swappable power supplies and a split backplane
system. For more information, see the Power Supply and Passive Backplane Addenda.
1. Airflow Vents
2. Chassis Body
3. Top Cover
4. Air Filter Compartment
5. Media Drawer
6. 5¼” Drive Bays (4)
7. 3½” Floppy Drive
8. Media Drawer Handle
9. Control Area Door
A. Power On/Off Switch
B. Right Power Supply LED (Green)
C. Power Supply Fault Alarm Stop Button
D. Left Power Supply LED (Green)
E. System Power LED (SBC 2)
F. Drive Activity LED (SBC 2)
G. System Power LED (SBC 1)
H. Drive Activity LED (SBC 1)
I. System Reset Button (SBC 1)
J. System Reset Button (SBC 2)

Operations
46200
plus Series Service Manual
Figure 2 Rear Features
Note: This illustration shows components for dual hot-swappable power supplies and a split backplane
system. For more information, see the Power Supply and Passive Backplane Addenda.
1. Airflow Vents
2. Chassis Body
3. Top Cover
4. Expansion Slots (20)
5. Serial Port Access (SBC 1)
6. Parallel Port Access (SBC 1)
7. AT Keyboard Connector (SBC 1)
8. Power Supply Bay
9. Serial Port Access (SBC 2)
10. Parallel Port Access (SBC 2)
11. AT Keyboard Connector (SBC 2)

Operations
Service Manual 6200plus Series 5
Specifications
Overview Listed in the table below are the specifications for the 6200plus series chassis.
Note: These specifications are subject to change without notice.
Environmental Environmental tolerances are listed in the following table:
System System specifications are listed in the following table:
Operating Non-Operating
Temperature 0 to 45 °C (32 to 113 °F) -40 to 70 °C (-40 to 158 °F)
Humidity 5 — 95% @ 40 °C, non-condensing 0 — 95% @ 40 °C, non-condensing
Shock 1 G @ 10 ms 10 G @ 10 ms
Vibration 0.25 G @ 5 — 200 Hz 1 G @ 5 — 200 Hz
Altitude 15,000 ft (4,572 m) 50,000 ft (15,240 m)
Dimensions
(Figure 3)•Benchtop: 17.1” W x 10.5” H x 17.8” D (434 x 267 x 452 mm)
•Rack-mount: 17.1” W x 10.5” H x 19.1” D (434 x 267 x 485 mm)
•Tower: 10.5” W x 18.3” H x 17.8” D (267 x 464 x 452 mm)
Note: The hot-swappable power supply handle adds 1.365” (34.7 mm) to the
depth of the chassis.
Construction Zinc-plate, powder-coated steel
Indicators
and Controls •System reset button
•System power LED
•Drive activity LED
Note: Dual reset buttons and LED’s are provided for a split backplane system.
•Power supply LED
•Power supply fault Alarm Stop button
Note: The power supply alarm features function only with the hot-swappable
power supply option.
•Rocker-style power ON/OFF switch
Keyboard AT-style connector on rear panel
Note: Dual connectors are provided for split backplane systems.
Peripherals Access for serial and parallel ports on rear panel
Note: Dual access is provided for split backplane systems.
Cooling •Three (3) 90 CFM fans
•Air filter (removable and washable)
•A fan within each power supply
Media •Removable:
•Four (4) 5¼” x 1.72” and
•One (1) 3½” x 1”
•Internal:
•Two (2) 3½” x 1” or
•One (1) 3½” x 1.6”
Expansion Twenty (20) slots, including SBC

Operations
66200
plus Series Service Manual
0.000
0.000
Tower Base
19.101
17.821
16.996
12.895
1.365
9.270
0.000
5.645
2.020
0.000
10.301
5.086 0.000
17.110
19.186
10.460
8.980
6.730
3.730
1.480
0.000
18.060
0.950
19.010
Figure 3 Dimensions
A Note on Thermal Specifications
The technology and power density of the microprocessor is rapidly increasing. The 80386 required less than a few hundred milliampere of
current. The 80486DX4 peaked at less than 1.5 A and dissipated less than 5 watts of power. The 233 MHz Pentium®processor with
MMX™ technology requires up to 6.5 A and dissipates as much as 17 W. The Pentium II processor dissipates even more. Power levels
have increased to a level that greatly affects the ability of the equipment to effectively dissipate energy.
RadiSys is continually working to ensure that its products will conform to thermal specifications. However, we can only work within known
or anticipated hardware and software configurations. One peripheral device installed within a chassis can significantly alter operating
temperature. Also, software applications can cause variations of 20 °C or more. Even the cable layout within the chassis can affect airflow
and thereby performance.
RadiSys validates the operating specifications of its products by testing with the “hottest” possible hardware and software configuration, to
maximize the power supply draw and generate a worst-case scenario. Despite these efforts, the specifications herein are only
benchmarks and should be regarded as such.

Service Manual 6200plus Series 7
Service
This chapter provides information on the following:
•Internal features
•Drives and media
•Passive backplane configurations
•Power supply configurations
•Air filter
•Fan module
This chapter also provides information on the components for each model of the
6200plus series chassis:
•Benchtop feet
•Rack-mount handle brackets and slide rails
•Tower base
2
This chapter discusses functions and features of the equipment that
can be accessed only by qualified and trained electronics service
personnel. The material contained in this chapter does not discuss any
user-accessible parts or operations. All tasks related to material in this
chapter must be referred to qualified service personnel.

Service
86200
plus Series Service Manual
Accessing the Interior
Safety It is important to protect yourself and your equipment.
Remove Power The 6200plus can be equipped with several power supply configurations. See page 26 for
information on removing power from the system.
Remove Top
Cover The procedure for removing the top cover of the 6200plus series chassis (Figure 4) is
outlined in the following table:
Only qualified, experienced electronics service personnel should access and handle
the equipment.
Es sollte nur qualifiziertes und erfahrenes Fachpersonal am System arbeiten.
To avoid damage or injury, always power-off the system and disconnect all power cords
from their source before handling the equipment.
To help prevent accidental damage caused by static discharge, use a grounding wrist
strap or other static-dissipating device when handling the equipment.
Um Sachschaden und Verletzung zu vermeiden, schalten Sie vor Arbeiten am Gerät
den Netzschalter aus, und ziehen Sie alle Stecker aus den Steckdosen.
Um unbeabsichtigte Schäden durch elektrostatische Entladung vorzubeugen, sollte bei
Arbeiten am System immer ein Erdungsarmband getragen oder andere
elektrostatische Entladungs-Vorsichtsmaßnahmen verwendet werden.
Step Action
1 Remove the three (3) screws from the rear of the top cover.
2 Loosen (but do not remove) the six (6) screws securing the left and right sides
of the top cover.
3 Rotate the rear portion of the top cover upward approximately ten degrees
(10°).
4 Slide the top cover away from the front panel and off the two guide pins on the
inside of the front panel.
5 Lift the top cover away from the chassis.
Do not remove the top cover from the tower model with the chassis in the
upright position. Before removing the top cover, lay the chassis on its “side,”
with the top cover facing upward. See Figure 22.

Service
Service Manual 6200plus Series 9
Figure 4 Removing the Top Cover

Service
10 6200plus Series Service Manual
Internal Features
Overview The 6200plus series chassis is designed to be flexible yet practical. The interior of the
chassis allows easy access to components and peripherals.
Passive
Backplane The 6200plus provides up to twenty (20) expansion slots with a variety of passive
backplanes, presenting a broad assortment of ISA and PCI slot configurations. The
6200plus also supports single or dual SBC operations utilizing a split backplane
configuration.
See the Passive Backplane Addendum for more information.
Media The 6200plus incorporates a removable media drawer that can contain:
•Four (4) user-accessible 5¼” x 1.72” drives
•One (1) user-accessible 3½” x 1” drive, typically a floppy disk drive
•Two (2) 3½” x 1” drives or one (1) 3½” x 1.6” drive
For more information on drives and media, see page 16.
Cooling The 6200plus provides excellent internal cooling with the following features:
•Removable fan tray containing three (3) 90 CFM cooling fans
•Removable and washable filter for air intake
For more information on the fan tray and air filter, see page 21 and page 24.
Power Supply The 6200plus also offers a variety of power supplies, supporting multiple input voltages.
Each power supply is equipped with features such as over voltage and over current
protection, and a high-volume cooling fan.
Hot-swappable power supplies are also available. Dual power supplies can be installed
for independent redundancy. Alarming features are also incorporated into the chassis.
See the Power Supply Addendum for more information.
Cable Access Access for cable routing is provided at the following locations in the chassis:
•Backplane Mounting Tray (Figure 5): cables can be routed above and below the
backplane tray at the front of the tray or through the four (4) access holes in the tray.
•Card Guide Bracket (Figure 6): the cooling fan power supply cable can be routed
through the access hole in the card guide bracket.

Service
Service Manual 6200plus Series 11
Figure 5 Internal Features
1. I/O Panel with 20 Expansion Slots
2. Passive Backplane Tray
3. Backplane Mounting Posts (17)
4. Cable Access Holes (4)
5. Speaker (SBC 1)
6. Speaker (SBC 2)
7. Electrical Grounding Post
8. Card Guide Bracket
9. Card Guides (up to 20)
10. Removable Fan Tray
11. Chassis Cooling Fans (3)
12. Top Cover Guide Pins (2)

Service
12 6200plus Series Service Manual
Expansion Cards
Installation Before installing expansion cards into the 6200plus series chassis, consult the
documentation provided with each card. Follow the manufacturer’s instructions for
installing the card.
Card Guide A full-length expansion card will reach from the expansion slot at the I/O panel of the
chassis to a card guide mounted on the card guide bracket. The card guide reduces
lateral movement that can dislodge the expansion card.
The card guides can be individually positioned on the card guide bracket to hold either
ISA, PCI, or non-standard, extended-length PCI cards (Figure 6).
Figure 7 shows examples of how card guides can be positioned to accommodate
different ISA and PCI slot configurations.
Retention
Bracket The expansion card retention bracket extends from one side of the chassis, across the
tops of the expansion cards, to the opposite side of the chassis. The retention bracket
secures the expansion cards in place. The bracket is keyed to prevent improper
installation (Figure 8).
The retention bracket has two accessories:
•Card Retention Cushion: grips the top of full-height expansion cards.
•Card Retention Clamp: extends downward from the retention bracket to the top of
an expansion card which does not reach the height of the bracket.
Note: RadiSys provides an assortment of retention clamps to accommodate a
variety of expansion cards with odd dimensions. For more information, contact
RadiSys Technical Support (see page v).
The retention cushion and clamps greatly reduce lateral movement of expansion cards
and help prevent cards from being dislodged. The retention cushion and clamps are
adjustable, each fitting a series of mounting holes along the length of the retention
bracket (Figure 9).