Xycom 9457 User manual

9457
Industrial PC/AT™
Computer System
P/N 110355-001B
 1997 XYCOM, INC.
Printed in the United States of America
Part Number 110355-001B
XYCOM
750 North Maple Road
Saline, Michigan 48176-1292
[phone]

Xycom Revision Record
Address comments concerning this
manual to:
xycom
Technical Publications Department
750 North Maple Road
Part Number: 110355-001B Saline, Michigan 48176-1292
Revision Description Date
AManual Released 7/96
BManual Updated 6/97
Trademark Information
Brand or product names are registered trademarks of their respective owners.
Windows is a registered trademark of Microsoft Corp. in the United States and other countries.
Copyright Information
This document is copyrighted by Xycom Incorporated (Xycom) and shall not be reproduced or copied without
expressed written authorization from Xycom.
The information contained within this document is subject to change without notice. Xycom does not
guarantee the accuracy of the information and makes no commitment toward keeping it up to date.

i
Table of Contents
Chapter 1 – Introduction
Product Overview ........................................................................................................1-1
About This Manual......................................................................................................1-3
Unpacking the System................................................................................................1-3
System Components...................................................................................................1-4
Computer Module.....................................................................................................1-4
Monitor Module ........................................................................................................1-6
Quick Start-Up.......................................................................................................... 1-10
Regulatory Compliance.............................................................................................. 1-12
Chapter 2 – Testing
Checking System Setup..............................................................................................2-1
Initiating the Tests.......................................................................................................2-1
Preparing for the Tests ................................................................................................2-2
Running the Tests.......................................................................................................2-2
Chapter 3 – Installation
System Components...................................................................................................3-1
Preparing the System for Use......................................................................................3-4
Installing Internal Hardware Options ..............................................................................3-4
Installation and Removal of the CPU Board .................................................................3-4
Installing PC Boards .................................................................................................3-6
Installing the Front Floppy Kit....................................................................................3-6
Installing a Device in the 5.25" Drive Bay ....................................................................3-9
Installing External Hardware Options........................................................................... 3-11
Installing the Remote Mount Kit............................................................................... 3-11
Installing Keyboard Cable Clamps............................................................................ 3-13
Installing Operating Systems ..................................................................................... 3-14
Installing Drivers........................................................................................................ 3-14
Video Drivers.......................................................................................................... 3-15
Mouse Drivers ........................................................................................................ 3-15
Touch Screen Drivers.............................................................................................. 3-15
CD-ROM Drivers..................................................................................................... 3-16
Miscellaneous Drivers ............................................................................................. 3-16
General Installation and Mounting Considerations ........................................................ 3-16
System Power ....................................................................................................... 3-17
Excessive Heat ...................................................................................................... 3-18
Excessive Noise..................................................................................................... 3-18
Excessive Line Voltage........................................................................................... 3-18
Installing the System into a Panel .............................................................................. 3-19
Mounting the Computer Module to the Monitor Module ................................................. 3-21
Removing the Computer Module................................................................................. 3-22
Derating the Power Supply......................................................................................... 3-23

9457 Industrial Computer
ii
Chapter 4 – System Operation
Using the Keypads......................................................................................................4-1
Using the Built-in Mouse..............................................................................................4-1
System Status LEDs ..................................................................................................4-2
Adjusting the Monitor ..................................................................................................4-3
On-Screen Display Mode Options.................................................................................4-3
Power Management Modes..........................................................................................4-5
Degaussing the Monitor...............................................................................................4-6
Chapter 5– Programmable Keypad Utility Program
Loading the Programmable Keypad Utility.....................................................................5-1
Using the Programmable Keypad Utility........................................................................5-1
Startup....................................................................................................................5-2
Utility Batch Mode....................................................................................................5-2
Main Menu.................................................................................................................5-3
Exit.........................................................................................................................5-3
Files Menu...............................................................................................................5-3
Macros Menu...........................................................................................................5-4
Upload Menu............................................................................................................5-8
Download Menu........................................................................................................5-8
Utilities Menu...........................................................................................................5-9
Codes...................................................................................................................... 5-10
Chapter 6 – Maintenance
Preventive Maintenance...............................................................................................6-1
Care of the 9457 Cabinet...........................................................................................6-2
Changing the Fan Filters ...........................................................................................6-2
Chemical Compatibility................................................................................................6-3
Compatible Lubricants ..............................................................................................6-5
Compatible Cleaning Agents......................................................................................6-6
Non-compatible Cleaning Agents ...............................................................................6-6
Spare Parts List..........................................................................................................6-7
Product Repair............................................................................................................6-8
Preparing the Unit for Shipment .................................................................................6-8
Appendix A – Specifications
Environmental Specifications........................................................................................A-1
Hardware Specifications ..............................................................................................A-2
Default Video Modes ...................................................................................................A-3
Appendix B – Pinouts
Keyboard Connectors..................................................................................................B-1
Serial Ports................................................................................................................B-2
Host/LED Port ............................................................................................................B-3

Table of Contents
iii

United States FCC Part 15, Subpart B, Class A EMI
Compliance Statement
Note: This equipment has been tested and found to comply with 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 radiate radio frequency
energy and, if not installed and used in accordance with the 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 cor-
rect the interference at his own expense.
For European Users - WARNING
This is a Class A product. In a domestic environment this product may cause radio inter-
ference in which case the user may be required to take adequate measures.
Installation: Electromagnetic Compatibility Warning
This monitor has been tested to EN 61000-4-8 for immunity to 50 Hz, 3 A/m magnetic
fields. Magnetic fields of this magnitude have the potential to create slight “jitter” on the
display. This jitter is the result of the magnetic field affecting the electron beam, which is
inherent to CRT technology and so cannot be reduced through electrical design. In order
to minimize the potential for this effect, do not install the monitor near devices which can
be expected to create significant magnetic fields. Examples are devices with inductive
coils such as alarm bells, speakers, relays, transformers, motors, or conductors which are
expected to conduct high levels of current. If screen jitter occurs and is due to 60 Hz AC
power, then setting the monitor vertical refresh rate to 60 Hz may correct the problem.
Otherwise, set the vertical refresh rate to the highest possible frequency.
The connection of non-shielded equipment interface cables to this equipment will invali-
date FCC EMI and European Union EMC compliance and may result in electromagnetic
interference and/or susceptibility levels which are in violation of regulations which apply to
the legal operation of this device. It is the responsibility of the system integrator and/or
user to apply the following directions which relate to installation and configuration:
1. All interface cables must include shielded cables. Braid/foil type shields are recom-
mended. Communication cable connectors must be metal, ideally zinc die-cast back-
shell types, and provide 360° protection about the interface wires. The cable shield
braid must be terminated directly to the metal connector shell; ground drain wires
alone are not adequate.
2. Protective measures for power and interface cables as described within this manual
must be applied. Do not leave cables connected to unused interfaces or disconnected
at one end. Changes or modifications to this device not expressly approved by the
manufacturer could void the user’s legal authority to operate the equipment.

1-1
Chapter 1 – Introduction
Product Overview
The 9457 Industrial Computer System puts the power and versatility of an IBM
PC/AT-compatible computer in a package that is ideal for the factory floor and other
harsh environments. The Xycom 9457 Industrial PC/AT Computer System features an
open-architecture to meet a wide variety of applications where both a powerful PC and
durable industrial enclosure are required. The system integrates a computer card cage,
mass storage, display, keypads, and power supply in a truly industrial form factor.
The 9457 system includes a seven-slot passive backplane, a SVGA monitor, hard and
floppy disk drive facilities, and data entry and function keypads. The front panel is
sealed to NEMA 4/4X/12 standards, and the CRT is protected with an impact-resistant
shield. The open-architecture design accepts any IBM PC, XT, AT or PCI-compatible
cards.
The system is shipped with a Pentiumprocessor-equipped CPU board installed, the
specific configuration of which is determined when the system is ordered. The processor
board combines all the functions of a complete IBM PC/AT compatible computer on a
single, industrially-hardened circuit board.
A complete 9457 computer system consists of two components: a computer module and
a monitor module. This modular design allows easy access to the boards, switches,
power supply and disk drives mounted in the computer module without removing the
monitor module. Once mounted, the computer module is easily removed by loosening
two thumb screws and sliding it out from under the monitor module.
The computer module provides the following standard features:
•A passive backplane featuring four ISA and two PCI slots for user expansion.
•CPU card featuring high-speed Pentium processor technology
•High-capacity IDE hard disk drive
•3.5-inch, 1.44 Mbyte floppy drive
•MS-DOS installed on the hard disk
•200-watt power supply
•IBM PC/AT/XT compatibility
•Parallel printer port
•Two RS-232C serial ports
•Integrated PCI video support

9457 Industrial Computer
1-2
•One user-configurable rear-accessible 5.25" drive bay (used by CD-ROM drive op-
tion if purchased)
•One user-configurable front-accessible 3.5" drive bay
The monitor module provides the following standard features:
•17" diagonal SVGA CRT with .28 mm dot pitch
•Variable scan frequencies in the following ranges:
•45 Hz to 125 Hz vertical scan frequency
•15 KHz to 125 KHz horizontal scan frequency
•1280 ×1024 maximum resolution (at 60 Hz), non-interlaced
•Digitally-controlled “On-Screen Display” monitor adjustments
•NEMA 4/4X/12 sealed front panel
•Front- and rear-mounted PS/2-compatible keyboard connectors
•Hard drive and serial port activity, power, fault and maintenance LEDs
The monitor module is available in a configuration featuring sealed keypads and a
mouse. This model also includes
•30-position sealed function keypad with full alpha capability
•28-position sealed numeric entry and cursor control keypad
•Alpha lock indicator LED
•Integrated mouse
A configuration featuring an analog touch screen is available, without keypads or an in-
tegrated mouse.
Optional items available for use with the 9457 include
•Touch screen (includes Windows 3.1 and Window 95 drivers)
•Windows®95 or Windows NT™ operating systems
•Larger hard drives
•Solid state (Flash) drives
•CD-ROM drive
•4100-KB2 External full-stroke keyboard*
•8000-KB5 Panel-mount 104-key keyboard*
•8000-KB7 Stand-alone 104-key QWERTY NEMA 4 sealed keyboard*
•4100-WIN Microsoft Windows
•9457-RMKRemote mounting kit
•9457-FFK Front-mount floppy drive kit
•9457-RF 19" Rack filler panel

Chapter 1 – Introduction
1-3
•9457-RFC 19" Rack filler panel with cutout for front-mounted floppy drive.
*These peripheral devices are not CE compliant.
About this Manual
This manual describes the 9457 Industrial PC/AT computer system. As the 9457 sup-
ports a variety of processor and peripheral options, refer to the documentation that ac-
companied the particular processor board or peripheral for information specific to that
component.
Unpacking the System
The 9457 is shipped in two cartons. One contains the computer module, and the other the
monitor. As you remove each from its shipping carton, verify that you have the parts
listed below. It is a good idea to save the boxes and inner wrapping in case you need to
reship the units.
The 9457 computer module carton contains
•9457 computer module
•Documentation kit, which includes
•Power cable
•Diagnostic software disk
•Processor card manual
•Display drivers disk
•9457 user manual
•Business reply card
If you ordered operating system software, you will receive operating system disks and
manuals.
The monitor module carton should contain
•9457 monitor module
•3-foot (914.4 mm) monitor power cable
•18-inch (457.2 mm) video cable
•24-inch (609.6 mm) Host/LED cable
•2 steel half-clamps
•14 - #10-32 nuts
•1 - #6-32 screw
If you ordered the system with a touch screen installed, you will receive
•Touch screen driver disk and manual

9457 Industrial Computer
1-4
Note
Windows NT and OS/2 drivers must be ordered separately
•18-inch (457.2 mm) touch screen (serial) cable
If you ordered the system with a built-in mouse, you will receive
•Mouse driver disk and manual
•18-inch (457.2 mm) mouse (serial) cable
If you ordered the system with a CD-ROM installed, you will receive a CD-ROM driver
disk.
System Components
Computer Module
Front
Figure Chapter 1 -1 illustrates the features on the front of the 9457 computer module.
Fan Intake
Filters
(
2
)
Front Drive
Bay
Figure Chapter 1 -1. 9457 Computer Module Front Components

Chapter 1 – Introduction
1-5
Fan Intake Filters These replaceable filters separate particulate contaminants
from the cooling air drawn into the 9457.
Front Drive Bay This bay may hold a single 3.5" externally-accessible mass
storage device, such as a floppy drive or tape back-up unit.
To install a device in this bay, you must install the 9457-FFK
Front Floppy Kit.
Rear
Figure Chapter 1 -2 illustrates the features on the rear of the 9457 computer module.
100-120V ~ 3A MAX .
200-240V ~ 3A MAX .
H
O
S
T
/
L
E
D
KEYBOARD
C
O
M
2
C
O
M
1
o
I
5.25" Bay
(optional CD-ROM)
3.5"
Floppy
Drive
ON/OFF
Switch
Serial
Ports
Cooling
Grille
Keyboard
Port
Host/LED
Connector
Power
Receptacle
Monitor Auxiliary
Outlet
Figure Chapter 1 -2. 9457 Computer Module Rear Components
ON/OFF Switch This switch should be positioned to OFF (O) until the system
is properly configured and connected to a 115 VAC or
230 VAC power source.
Cooling Grille Unobstructed airflow is essential to proper ventilation and
cooling of the 9457. Do not obstruct this outlet.
Power Receptacle The plug and cord must be securely positioned before turning
power ON.
Monitor Auxiliary
Outlet
This switched outlet may only be used to power the 9457
monitor module or a monitor or other device that draws less
than 3.0 A peak current.

9457 Industrial Computer
1-6
Serial Ports The serial port connectors are a pair of male DB-9 connectors
located above the keyboard connector. As shipped, these are
configured as COM1 and COM2, in the manner labeled on
the back panel.
Keyboard Port This six-pin mini-DIN connector allows a PS/2-compatible
keyboard to be directly connected to the 9457 computer
module.
Use of this port is not recommended. If an external keyboard
is desired, use the External Keyboard port or the Keyboard In
port on the Monitor Module.
Note
Do not connect a keyboard to the keyboard port on the back of the 9457 computer
module if the computer module is connected to the monitor module using the
Host/LED cable.
Only connect a keyboard to this port if the computer and monitor modules are not
connected using the Host/LED cable.
Host/LED Connector Connect the 15-pin Host/LED cable from the 9457 monitor
module to this socket.
Monitor Module
Front Panel
The 9457 monitor module is equipped with a NEMA 4/4X/12 sealed front panel. The
panel protects the system’s interior when the system is properly panel mounted. See
Chapter 3 for panel-mounting instructions. Figure Chapter 1 -3 illustrates the front panel
features of the 9457 monitor module.

Chapter 1 – Introduction
1-7
FAULT MAINT POWER DISK COM
ABCD
KLMN
EF
OP
GH I
QRS
UVW X Y Z
/
SPACE
:\
PAUSE INS
BACK
SPACE A
J
T
()
#*
Function/Alpha
Toggle Key
Industrial
Mouse
Status
LEDs
External Keyboar
d
Port
Figure Chapter 1 -3. 9457 Monitor Module Front Panel
Monitor Protected from breakage by an impact-resistant shield, the 17"
monitor supports high-resolution SVGA color modes. If the
touch screen option is installed, the shield is replaced by a
safety glass-backed touch panel.
Function/
Alpha Keys
These 30 keys provide the user with an easy means of entering
text data, and easy access to familiar PC routines. These keys
are located directly below the monitor.
On models ordered without keypads, this panel contains only
the system status LEDs.
Data Entry Keypad This 28-key numeric keypad includes 15 data entry keys; the
up, down, left, and right arrows; and numbers 0-9.
On models ordered without keypads, this panel is blank.
External Keyboard
Port
This six-pin mini-DIN connector allows you to connect a
PS/2-compatible keyboard to the 9457 monitor module. For
this feature to function, the Host/LED cable must be connected
between the port on the back of the 9457 monitor module and
the Host/LED port on the back of the 9457 computer module.

9457 Industrial Computer
1-8
Caution
When not using a keyboard connected to the front keyboard port on the 9457 monitor
module, always keep the keyboard port capped using the attached plug. Leaving the
keyboard port uncapped defeats the NEMA-compliant seal feature incorporated into
the design of the 9457 monitor module.
Left Mouse Key This key serves the same function as the left button on a conven-
tional mouse.
Mouse Dome This dome is used to move the mouse pointer around the screen.
Press the edge of the dome that corresponds to the direction in
which you wish to move the pointer.
Right Mouse Key This key serves the same function as the right button on a conven-
tional mouse.
Status LEDs Indicate the state of the computer, as described in Chapter 4, Sys-
tem Status LEDs.
Rear
Figure Chapter 1 -4 illustrates the rear components of the 9457 monitor module.
Keyboard
In Port
Keyboard
Out Port
Host/LED
Connector
Touch Screen
Port
Mouse
Port
Video Input
Port
Power
Receptacle
Contrast
Knob
Brightness
Knob
Degauss
Button
On-Screen
Display
Button
Soak Test
Button
HOST/LED MOUSE VIDEO
TOUCH
SCREEN
Cooling
Grille
Figure Chapter 1 -4. 9457 Monitor Module Rear Components

Chapter 1 – Introduction
1-9
Cooling Grille Unobstructed airflow is essential to proper ventilation and
cooling of the 9457. Do not obstruct this outlet.
Keyboard In Port This port provides a location to connect a standard
PS/2-compatible keyboard to the back of the 9457 monitor
module.
Keyboard Out Port This six-pin mini-DIN connector allows you to connect a
PS/2-compatible keyboard cable between the monitor module
and a computer module.
Use of this port is not recommended, since in normal opera-
tion, keyboard signals are transmitted through the Host/LED
connector.
Note
When connecting the monitor module to the computer module, use either the supplied
Host/LED cable or a cable between the monitor module’s Keyboard Out port and the
computer module’s Keyboard port, but not both. Using both cables will cause the key-
board to operate improperly.
Host/LED Connector Connect the 15-pin Host/LED cable from the 9457 computer
module to this socket. This connector provides the power,
keyboard, and LED signals to the monitor module’s front
panel.
Touch Screen Port If the 9457 monitor module comes equipped with a touch
screen, you must connect a cable between this connector and
either the COM1 or COM2 connector on the 9457 computer
module.
Mouse Port If the 9457 monitor module comes equipped with a built-in
mouse, you must connect a cable between this connector and
either the COM1 or COM2 connector on the 9457 computer
module.
Power Receptacle The plug and cord must be securely positioned before turning
power ON.
Video Input Port This 15-pin high-density female connector is used to connect
the 9457 monitor module to the video output of the 9457
computer module.

9457 Industrial Computer
1-10
Video Controls The video controls consist of two knobs and five buttons.
These are, from left to right:
Contrast knob – Turning this knob adjusts the contrast on
the display.
Brightness knob – Turning this knob adjusts the brightness
of images on the display.
Degauss button – Used to manually degauss the monitor.
Use of this control is described in Chapter 4.
Soak Test button – This button is not used during normal
operation.
On-Screen Display mode button – This button is used to
select On-Screen Display mode to adjust the vertical size,
horizontal position and vertical position of the image on the
display. This mode is described in the On-Screen Display
Mode Options section in Chapter 4.
Note
The pinouts for connectors and ports are shown in Appendix B.
Quick Start-Up
Note
This section gets your 9457 up and running without explaining the capabilities and
options of the system. The appendices provide technical specifications, diagrams, and
other information required for system operation.
Chapter 3 contains important safety information describing requirements for the safe
operation of this product. Xycom strongly recommends that you read Chapter 3 be-
fore mounting the 9457 in a panel, or otherwise placing it into regular service.
To prepare the system for use, perform the following steps.
Warning
Turn off the power to the unit and unplug the power cord before making any adjust-
ments to the inside or outside of the computer.
1. Install any additional cards you wish to use in the computer module, then reassemble
the unit.

Chapter 1 – Introduction
1-11
2. Connect the video cable from the 15-pin video input connector on the monitor mod-
ule to the 15-pin video output connector on one of the processor board ORBs on the
computer module.
3. Connect the Host/LED 15-pin cable from the Host/LED connector on the monitor
module to the Host/LED connector on the computer module.
4. If you wish to use an external keyboard, connect it to the port on either the front or
rear of the monitor module.
Note
If you connect a keyboard to the rear keyboard connector on the computer module,
Do not connect the Host/LED cable between the monitor module and the computer
module. Doing so will cause improper keyboard operation.
5. If the monitor module is equipped with a touch screen, connect a nine-pin cable from
the touch screen port on the monitor module to the COM1 port on the computer
module.
Note
By default, the driver software for the touch screen is set to communicate with the
touch screen through serial port COM1. If you connect the touch screen to any other
serial port, you will need to set the driver software to use that port. Refer to the in-
structions accompanying the driver disk for more details.
6. If the monitor module is equipped with a mouse, connect a nine-pin cable from the
mouse port on the monitor module to the COM2 port on the computer module.
7. Attach any other optional equipment following the instructions in Chapter 3.
8. Connect the monitor module power cord from the power receptacle on the monitor to
the monitor auxiliary outlet on the computer module.
9. Connect the computer module power cord from the power receptacle to a properly
grounded 115/230 VAC, 50/60 Hz outlet. Attach the power cord to the lower power
receptacle.
10. Turn on power to the unit by pressing the On/Off switch in.
11. Set the contrast and brightness controls on the back panel of the monitor module to
the desired levels.
12. Install driver and application software via drive A:.

9457 Industrial Computer
1-12
Regulatory Compliance
The Xycom 9457 Computer is UL and CUL recognized and has been investigated for
compliance with the following standards:
Agency Approvals
•UL UL 1950 (Information Technology Equipment)
•CUL CSA 22.2, #950 (Information Technology Equipment)
Regulatory Compliance
•EU “CE Marking” EMI EN 55022, Class A
Immunity EN 50082-2
Safety EN 60950
•FCC 47 CFR, Part 15, Class A
•Industry Canada ICES-003, Class A
The manufacturing facility Xycom, Inc. maintains at Saline, Michigan is ISO 9001
Quality System certified, and is accredited by ANSI-RAB and the RvA.

2-1
Chapter 2 – Testing
Diagnostic tests are provided as a tool to verify the operation of the 9457 system hard-
ware functions. If any of these tests fail, either you do not have the correct default setting
or there is a failure. Check the default settings and run the tests again. If there is a failure,
contact Xycom’s Product Repair Department.
Note
Unexpected failures may occur if Xycom diagnostics are run with device drivers or
memory resident programs installed on the system. Remove these before running any
diagnostic tests.
Also, the diagnostic disk does not provide an option to test a CD-ROM drive.
Checking System Setup
Make sure the Setup Menu is configured properly (factory-set configuration). To enter
the Setup Menu, press F2, and then press F2 to display the Main Menu. Make the neces-
sary changes by following the on-screen directions. General instructions for navigating
through the Setup screens are described below:
•ÅÇÈÆmove the cursor left, up, down, and right. Press ENTER to validate your se-
lection.
•ESC exits the menu. You are prompted to save changes.
•F5 selects the previous or smaller value.
•F6 selects the next or higher value.
•F9 automatically configures the system with the default values. These values are de-
fined by the system configuration and the values are set in the Setup Menu.
•F10 loads previous values.
Initiating the Tests
To test your system, you need the following equipment.
•Xycom System Test Disk—3.5-inch, DS/HD disk (bootable), part number 99290-001
•IBM PC/AT-compatible keyboard (Xycom P/N 91971-001 or equivalent)
•Centronics-compatible printer cable