SeaLevel Relio Fanless Core 2 Duo R5200 Series User manual

1
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Relio Fanless Core
™2 Duo R5200 Series
User Manual | R5220 – 2 GB RAM & R5240 – 4 GB RAM

2
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Contents
CONTENTS...........................................................................................................................................................2
BEFORE YOU GET STARTED ............................................................................................................................... 3
INTRODUCTION ................................................................................................................................................... 6
HARDWARE INSTALLATION ...............................................................................................................................8
TECHNICAL DESCRIPTION MOTHERBOARD LAYOUT – COMPONENT SIDE ...............................................20
SPECIFICATIONS ...............................................................................................................................................39
APPENDIX A – HANDLING INSTRUCTIONS ....................................................................................................40
APPENDIX B – PHOENIX AWARD BIOS ...........................................................................................................41
APPENDIX C – BOOTING FROM A USB DRIVE ................................................................................................67
APPENDIX D – WATCH DOG TIMER.................................................................................................................73
APPENDIX E – HOW TO GET ASSISTANCE .....................................................................................................74
APPENDIX F – SERIAL INTERFACES................................................................................................................75
WARRANTY ........................................................................................................................................................76

3
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Before You Get Started
What’s Included
The Relio R5200 is shipped with the following items. If any of these items is missing or damaged, please
contact Sealevel for replacement.
•Relio R5200 Series Fanless Core 2 Duo Computer
oR5220 includes 2GB RAM
oR5240 includes 4GB RAM
•100-240V AC to 24VDC @ 120W Desktop Power Supply
•US Power Cord for Desktop Power Supply
Advisory Conventions
Warning
The highest level of importance used to stress a condition where damage could result to the
product, or the user could suffer serious injury.
Important
The middle level of importance used to highlight information that might not seem obvious or a
situation that could cause the product to fail.
Note
The lowest level of importance used to provide background information, additional tips, or other
non-critical facts that will not affect the use of the product.

4
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Optional Items
Depending upon your application, you are likely to find one or more of the following items useful for
interfacing the Relio R5200 to real-world signals. All items can be purchased from our website
(www.sealevel.com) or by calling [phone].
Terminal Blocks:
DB9 Female to 9-Screw Terminals (Part# TB05)
The TB05 terminal block breaks out a DB9 connector to 9 screw
terminals to simplify field wiring of serial connections. It is ideal
for RS-422 and RS-485 networks, yet it will work with any DB9
serial connection, including RS-232. The TB05 includes holes
for board or panel mounting. The TB05 is designed to connect
directly to Sealevel DB9 serial cards or any cable with a DB9M
connector.
DB9 Female to RJ45 Modular Adapter (Part# RJ9S8)
DB9 Female to RJ45 Modular Adapter. Excellent choice for
using available infrastructure wiring. Item ships unassembled
and can be easily configured without tools.
Memory Options/Upgrades:
Relio R5200 systems have two 240-pin DIMM slots. The first slot includes 2GB RAM and ordering
options allow for a maximum of 4GB. It is recommended to order the R5200 system with memory
already integrated. The following memory is recommended for field replacement or upgrades.
1GB DDR2 240-Pin DIMM (Part# RAM1GB-667X240)
1GB DDR2 240-pin DIMM (667MHz Non-ECC CL5) module.
2GB DDR2 240-Pin DIMM (Part# RAM2GB-667X240)
2GB DDR2 240-pin DIMM (667MHz Non-ECC CL5) module
(one included in Relio R5220 and two included in Relio R5240).

5
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
SATA Solid-State Disk (SSD) Drives:
Install your operating system and application on 2.5” SSD drives for true solid-state operation resulting
in the highest reliability. Integration options are available. Contact your sales representative for details.
16GB SATA Solid-State Disk (Part# SSD-16GSS)
16GB 2.5” SATA SSD with MLC memory.
32GB SATA Solid-State Disk (Part# SSD-32GMS)
32GB 2.5” SATA SSD with MLC memory.
64GB SATA Solid-State Disk (Part# SSD-32GMS)
64GB 2.5” SATA SSD with MLC memory.
128GB SATA Solid-State Disk (Part# SSD-128GMS)
128GB 2.5” SATA SSD with MLC memory.

6
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Introduction
The Relio R5200 fanless, dual-core industrial computer is designed for CPU-intensive applications in
industrial environments. Available with a fanless 2.2GHz Intel® Core™2 Duo processor and up to 4GB RAM,
the R5200 offers first-class performance and reliability. The system offers a wealth of standard I/O features
including dual Gigabit Ethernet, six USB 2.0 ports, four serial ports, and VGA video. Expansion options
include one full-height PCI slot and one PCI Express x16 slot.
An optional 2.5" solid-state SATA hard drive can be integrated and preloaded with Microsoft Windows or
Windows Embedded operating systems. Linux is also supported. With your operating system and
application running from solid-state hard drive, the R5200 provides the ultimate in reliability — no moving
parts.
The R5200 includes an external power supply and US power cord that accepts 100-240V AC input and
outputs 24VDC @ 120W. The metal enclosure allows for versatile mounting to walls, under counters, and
on tabletops.
Features
Relio R5200 systems are designed for CPU-intensive applications in industrial environments and include
the following features:
Standard System Features
•Compact, rugged enclosure with silver-colored finish
•Solid-state operation with no fans or other moving parts
•Includes 2.2GHz Intel® Core™2 Duo processor and 2GB RAM.
•Mini-ITX motherboard with Intel® 965GME, VGA, and dual Gigabit LAN
•Up to 4GB RAM (DDR2 533/667MHz 240-Pin DIMM, Non-ECC, CL5) via two DIMM slots
•Hardware (965GME GMA X3100) integrated graphics supports QXGA resolution up to
2048x1536 @ 75Hz and 32-bit color.
•2.5" internal shock-mounted hard drive bay is perfect for optional solid-state disk
applications.
System Monitoring and Management
•Battery backed RTC/CMOS
•Watchdog Timer with 255 levels (1-255 Seconds)
•Supports CPU thermal/voltage monitoring and management.
•Supports Wake on Ring and Wake on Alarm functions.
•System power management (OS dependent)

7
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Enclosure Front
•Two expansion slots support one PCI Express X16 and one PCI card.
•Two 10/100/1000BaseT RJ45 (Intel 82566DM, 82573V) Gigabit Ethernet ports with
status LEDs
•Four DB9M serial ports (COM1 = RS-232/422/485, COM2,3,4 = RS-232)
•Six USB 2.0 ports
•Two IEEE-1394 “FireWire” ports
•One analog VGA DB15 connector
•Separate PS/2 mouse and keyboard ports
•Audio line out and microphone in
•LED status indicators for power and disk activity
•On/Off power switch

8
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Hardware Installation
Follow proper ESD procedures by grounding yourself and the computer chassis before opening the
enclosure. This will help avoid system damage resulting from static electricity discharge.
Installing System Memory
The R5200 supports a maximum of 4GB RAM via two 240-Pin DIMM slots. The memory slots accept either
533MHz (CL4) or 667MHz (CL5) Non-ECC DDR2 memory.
The base system (R5220) includes 2GB 667 MHz RAM in the slot located on the top of the motherboard
under the heat sink. The system can be ordered with 4GB 667 MHz RAM (R5240) installed at the factory or
an additional 1GB or 2GB can be installed in the field.
To install memory into the second slot, follow these instructions:
1. Turn off the system and disconnect from power source.
2. Loosen the eight (8) screws located on the top of the system.

9
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
3. Remove the top cover (heat sink) from the chassis by lifting straight up. Thermal
conductive pads between internal heat sinks and the cover will make removal seem
difficult. Do not twist or slide the cover while attempting to remove.
4. With the cover removed, the two DIMM slots are located along one side. Locate the empty
memory socket.
5. Align the memory module with the socket. The socket is keyed so that memory can only
be installed one way.
6. Insert the memory module into the socket and push down firmly until seated. The socket
latches will clip into the edge of the DIMM module when seated correctly.
7. Replace the top cover and tighten the eight (8) screws.
8. Plug the system into the power source and power up the system.

10
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Installing a Solid-State Disk Drive
The R5200 offers a convenient shock-mounted drive tray that supports a single 2.5” SATA solid-state disk
(SSD) or hard drive. The drive tray is located in the middle of the enclosure and accessed through the side.
To install a 2.5” drive, follow these instructions:
1. Turn off the system and disconnect from power source.
2. Remove the three screws from the side of the enclosure.
3. Remove the side panel and locate the hard drive tray.

11
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
4. Remove the two screws securing the drive tray and then slide the tray out of the enclosure.
Keep the same side of the tray up and place it on an ESD safe surface.
5. Place the hard drive, label side down, within the drive tray bracket. The connectors on the
drive should face away from the flanges on the tray. Secure the drive to the tray using the
screws supplied by the drive manufacturer.
6. Slide the drive tray and drive back into the enclosure.
7. The SATA and power connectors will automatically engage the drive when the tray is
inserted correctly. Secure the drive tray using the two screws.
8. Replace the side cover and install the three screws.
9. Plug the system into the power source and power up the system.

12
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Installing Expansion Cards
The R5200 offers two expansion slots that support one PCI Express X16 and one 32-bit PCI card. The cards
are held securely in place by a bracket and screw.
Expansion Card Power Limits
Due to the embedded nature of this system, some power limitations exist that required to ensure
fanless operation. The thermal power design of the system limits how much power can be provided by
the internal power supply. Because of this power design limit, the PCIe and PCI expansion buses cannot
supply the power required by the appropriate PCI Specification. While neither bus can meet the full PCI
power specification both busses can supply sufficient power to operate all Sealevel Systems designed
expansion cards and many cards from other manufacturers. The actual power limits are listed in the
tables below. Verify that any expansion card does not require more power that listed below before
installing.
Voltage Rail PCI Maximum Current PCIe Maximum Current
-12V 100mA Not Used by PCIe
12V 500mA 4.48A
5V 2.5A Not Used by PCIe
3.3V 1.6A 2.74A
To install an expansion card into the R5200, follow these instructions:
1. Turn off the system and disconnect from power source.
2. Remove the three screws from the side of the enclosure and remove the side panel.

13
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
3. Turn the system on its side and remove the four screws securing the bottom cover.
4. On the front of the enclosure, remove the screw and the bracket holding the PC brackets
in place. The bracket is keyed and may have to be gently rocked back and forth to remove.
5. If installing multiple expansion cards, install the PCI card first due to the tight confines of
the enclosure.
6. Align the expansion card with the proper slot and press the card into the slot until firmly
seated.

14
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
7. On the outside of the enclosure, replace the bracket and secure with the screw. The
image shows two expansion cards properly installed.
8. Replace the bottom cover and secure with the four screws. Replace the side cover and
secure with the three screws. Turn the system back onto its base.
9. Plug the system into the power source and power up the system.

15
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Installing optional cooling fan
Installation of a high power expansion card may require additional cooling to ensure the system can operate
reliably up to 40 degrees Celsius. If a PCIe expansion card dissipates more than 7 Watts inside the
computer an optional PCI slot exhaust fan (PN: PCF-5200-5.7) will likely be necessary to remove the extra
heat.
To install the exhaust fan into the R5200, follow these instructions:
1. Turn off the system and disconnect from power source.
2. Remove the three screws from the side of the enclosure and remove the side panel.
3. Loosen the eight (8) screws located on the top of the system.

16
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
4. Remove the top cover (heat sink) from the chassis by lifting straight up. Thermal
conductive pads between internal heat sinks and the cover will make removal seem
difficult. Do not twist or slide the cover while attempting to remove.
5. On the front of the enclosure, remove the screw and the bracket holding the PCI brackets
in place. The bracket is keyed and may have to be gently rocked back and forth to remove.
6. Remove the blank PCI bracket from the PCI slot.
7. Align the PCI bracket that the exhaust fan is mounted to with the opening in front of the
PCI slot and lower the fan into place ensuring the narrow section of the bottom edge of the
bracket drops into its landing zone to ensure secure mounting.

17
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
8. Route the power wires in the recessed area between the front chassis plate and ribbon
cables, as pictured, to ensure the wires are not pinched when the side of the enclosure is
reinstalled.

18
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
9. Plug the power cable into the fan header on the top side of the motherboards as pictured.
The header and connector have a keyed latching mechanism to ensure correct orientation
and polarity.
10. Gently pull any excess wire out of the expansion card area and lay it in the area on the top
side of the motherboard to ensure it does not interfere with airflow entering the fan.

19
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
11. On the outside of the enclosure, replace the expansion card locking bracket and secure
with the screw.
12. Replace the side cover and secure with the three screws (ensure the fan power cables are
not pinched). Turn the system back onto its base.
13. Replace the top cover (heat sink) with the eight screws. The following image shows a high
power third party PCI Express expansion card and exhaust fan properly installed.
14. Plug the system into the power source and power up the system.

20
© Sealevel Systems, Inc. R5220 & R5240Manual | SL9222 1/2023
Technical Description
Motherboard Layout – Component Side
The board map below shows the components that are located on the top of the motherboard, underneath
the top cover (heat sink). All configurable jumpers are accessible by removing the top cover.