Xycom 3500 Series User manual

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3500 Series Flat Panel
Industrial PC
with 6-slot ISA/PCI Expansion
P/N 350006(D)


2002 XYCOM AUTOMATION, INC. Printed in the United States of America

3500 Series Flat Panel Industrial PC
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Revision Description Date
A Manual Released 4/99
B Added 3515KPM 1/00
C Updated Bulb Replacement Instructions 11/00
D Touchscreen Updates 7/02
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 Automation Incorporated (Xycom Automation) and shall not be reproduced or copied without ex-
pressed written authorization from Xycom Automation.
The information contained within this document is subject to change without notice. Xycom Automation does not guarantee the accuracy of the
information and makes no commitment toward keeping it up to date.
United States FCC Part 15, Subpart B, Class A EMI Compliance Statement:
NOTE: 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 envi-
ronment. 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 correct 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 interference in which case the user may be required to take
adequate measures.
INSTALLATION: Electromagnetic Compatibility WARNING
The connection of non-shielded equipment interface cables to this equipment will invalidate 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 con-
figuration:
1. All interface cables must include shielded cables. Braid/foil type shields are recommended. Communication cable connectors must be
metal, ideally zinc die-cast backshell types, and provide 360 degree 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. For systems other than Pentium II logic board (AHIP6+): In those cases where an external mouse is used, the snap-on ferrite bead provided
(P/N 116046) must be installed on the mouse cable at the host end in order to comply with relevant EMI regulations.
3. 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 authority to operate the equipment.
4. EMC compliance is, in part, a function of PCB design. Third party add-on AT/XT peripheral PCB assemblies installed within this appara-
tus may void EMC compliance. FCC/CE compliant PCB assemblies should always be used where possible. XYCOM AUTOMATION can
accept no responsibility for the EMC performance of this apparatus after system integrator/user installation of PCB assemblies not manu-
factured and/or expressly tested and approved for compliance by XYCOM AUTOMATION. It is the responsibility of the system integra-
tor/user to ensure that installation and operation of such devices does not void EMC compliance.
Xycom Automation
Technical Publications Department
750 North Maple Road
Saline, MI 48176–1292
734-429-4971 (phone)
734-429-1010 (fax)

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Table of Contents
Chapter One – Introduction........................................................................................................................5
Product Overview......................................................................................................................................................5
With AHIP6+ board ...............................................................................................................................................5
With AHIP370+ board ...........................................................................................................................................5
On all units .............................................................................................................................................................5
Unpacking the System...............................................................................................................................................7
Quick Start-up ...........................................................................................................................................................7
Chapter Two – Testing................................................................................................................................9
Preparing for the Tests ..............................................................................................................................................9
Running the Tests....................................................................................................................................................11
Chapter Three - Installation......................................................................................................................12
System Components ................................................................................................................................................12
Installation Options .................................................................................................................................................20
SDRAM and Additional SDRAM Dual In-Line Memory Modules (DIMMs).....................................................20
PC/AT or PCI Boards...........................................................................................................................................20
Externally Mounted Floppy Drive........................................................................................................................21
Front Access Keyboard and Floppy Connectors...................................................................................................23
Serial AUX...........................................................................................................................................................25
Creating a Custom Logo..........................................................................................................................................25
3515......................................................................................................................................................................25
3512KPM/3515KPM ...........................................................................................................................................25
Creating Custom Keypad Inserts (3512KPM/3515KPM only)...............................................................................26
Installing Operating Systems...................................................................................................................................28
Installing Drivers.....................................................................................................................................................29
Using a Touchscreen ...............................................................................................................................................31
Video Expansion .....................................................................................................................................................35
Mounting Considerations ........................................................................................................................................36
AC Power Cable...................................................................................................................................................39
Cable Retainer Bracket.........................................................................................................................................41
Mounting the Unit ...................................................................................................................................................41
Hazardous Locations Installations...........................................................................................................................43
Class I Locations ..................................................................................................................................................44
Class II Locations.................................................................................................................................................44
Division 1 Locations.............................................................................................................................................45
Division 2 Locations.............................................................................................................................................45
Groups..................................................................................................................................................................45
Safety Agency Approval..........................................................................................................................................47
Chapter Four – Keypad Utility Program..................................................................................................48
Loading the Keypad Utility.....................................................................................................................................48
Using the Keypad Utility.........................................................................................................................................48
Main Menu..............................................................................................................................................................49
Keypad Scan Codes.................................................................................................................................................53
Chapter Five - Maintenance .....................................................................................................................57
Xycom Recommended Hard Drive Preventative Maintenance ...............................................................................57
Appendix A – Technical Specifications ..................................................................................................63

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Hardware Specifications..........................................................................................................................................63
Environmental Specifications..................................................................................................................................63
Appendix B – Block Diagrams .................................................................................................................65
Appendix C – Pinouts ...............................................................................................................................67
Keyboard Port Connectors ......................................................................................................................................67
Aux Port Connector.................................................................................................................................................67
Dual USB Connector (USB1) .................................................................................................................................67
Parallel Port Connector (LPT1)...............................................................................................................................68
Serial Port Connectors.............................................................................................................................................68
VGA Connector.......................................................................................................................................................69
External Floppy Connector......................................................................................................................................70
Appendix D – Replacing Flat-Panel Display Bulbs................................................................................71

Chapter Two - Testing
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Chapter One – Introduction
Product Overview
The 3500 series of flat panel industrial PCs with 6-slot ISA/PCI expansion include the
3515, 3515T, 3515KPM, and 3512KPM models. These industrial PCs offer a powerful,
compact package for the factory floor and other harsh environments. The 3515 is an in-
dustrial PC with a display only (touchscreen optional). The 3512KPM and 3515KPM is
an industrial PC with a display, integrated keypads, and an integrated mouse.
They feature an open architecture to meet a wide variety of applications that require both
a powerful PC and a durable industrial front panel. The PCs integrate a computer card
cage, mass storage, display, and power supply in a truly industrial form. Their modular
design allows easy access to expansion boards, jumpers, power supply, flat panel dis-
play, and disk drives.
The front panel of every model is sealed to NEMA 4/4X/12, and the flat panel display is
protected by an impact-resistant shield.
Standard Features
With AHIP6+ board
•Pentium® III technology
•PCI 64 bit video controller, 2 MB video RAM
•PCI local-bus IDE controller
•Two 168-pin SDRAM DIMMs that support 32, 64, 128, and 256 MB options
•Two USB ports
•100MHz front side bus with Pentium III processors
With AHIP370+ board
•Celeron ® technology
•AGP 64 bit video controller, 2 MB video RAM
•PCI local-bus IDE controller
•Two 168-pin SDRAM DIMMs that support 32, 64, 128, and 256 MB options
•Two USB ports
On all units
Two serial COM ports
•COM 1
•RS-232 or RS-485 (DB9 connector)
•RS-232 (DB25 connector)

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•Flat panel display
•15-inch flat panel, 1024x768 resolution (3515T and 3515KPM)
•12.1-inch flat panel, 800x600 resolution (3512KPM)
•Parallel port
•VGA port
•Flash BIOS
•9-inch mounting depth
•3.5-inch internal, side access floppy drive
•Six AT-bus full-length expansion slots
•Five ISA slots
•One PCI or four ISA slots
•Two PCI slots (4.8” maximum length with AHIP6+ board)
•IR Port (IrDA and ASKIR compatible)
•Rear PS/2 keyboard port and AUX port (also a front PS/2 keyboard port on
3512KPM and 3515KPM)
•Status LEDs
•Power
•Disk
•Com
•Input
•3.5-inch internal IDE hard drive
•MS-DOS®
•Front panel sealed to meet NEMA 4/4X/12 specifications when panel mounted in a
suitable fire and electrical enclosure.
•Approved for use in Class I, Division 2 hazardous locations
•Autosensing AC power supply
•Side power connector with retainer bracket
Optional Features
•Touchscreen resistive technology with less than 1.5% linearity error
•Higher capacity IDE hard drives and solid state drives
•3512KPM
•40 relegendable function keys (80 with the F/A function)
•Numeric, PC control, and alpha keypads
•Integrated mouse
•3515KPM
•40 relegendable function keys (80 with the F/A function)
•Numeric, PC control, and alpha keypads
•Windows start menu and pop-up menu keys
•Integrated mouse

Chapter Two - Testing
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•Flat-panel display
•15.0-inch TFT flat panel (3515 and 3515KPM)
•12.1-inch TFT flat panel (3512KPM)
•CD-ROM (internal)
•Pre-installed PCI 10/100 Base-T Ethernet card
•External floppy drive 9000-EXF
•Front mount floppy kit 9000-FFK
•Front access panel for floppy port and keyboard port 9000-FKA
•Preloaded Microsoft Windows 95 or Windows NT® operating system
Unpacking the System
When you remove the system from its box, verify that you have the parts listed below.
Save the box and inner wrapping in the event you need to reship the unit.
•3515, 3515KPM, or 3512KPM unit
•AC power connector
•Power connector retainer bracket with AC power supply
•Sixteen 10-32 hex nuts (2 spares)
•Clip-on Ferrite for AUX cables
•Documentation kit, which includes:
•Diagnostic software disk (only on units shipped with DOS)
•VGA utility disk
•3515/3512KPM manual
•CPU manual
•Business reply card
If you ordered the system with a touchscreen installed, you will also receive a touch-
screen driver disk and manual. If you ordered a CD-ROM installed, you will receive the
driver disk. If you ordered a 3512KPM or 3515KPM, you will receive a mouse disk and
manual. If you ordered the system with an Ethernet card you will receive a driver disk.
Quick Start-up
This section provides the steps to get your unit up and running without explaining the
capabilities and options of the system.
Warning
Turn off power to the unit and disconnect the power cord before making
any adjustments to the inside or the outside of the computer.
Perform the following steps to prepare the system for use.

3500 Series Flat Panel Industrial PC
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1. Attach an optional keyboard to the keyboard port.
2. Attach other optional equipment following the instructions in Chapter 3.
3. Attach the power cord from the power receptacle to a properly grounded 115/230
VAC, 50-60 Hz outlet or a 24 VDC outlet, whichever applies (Refer to the Creating
a Power Cable section in Chapter 3 for more information.)
4. Turn on the power to the unit. Depending on your operating system, one of the fol-
lowing will occur:
•In DOS, the system will boot up at the C: prompt
•In Windows 95 or Windows NT the License Agreement will be displayed
5. Install application software via the floppy, a network connection, the IR port, or a
CD-ROM.

Chapter Two - Testing
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Chapter Two – Testing
On units with MS-DOS installed, diagnostic tests are provided as a tool to verify the op-
eration of system hardware functions. If any of these tests fails, either you do not have
the correct default setting or there is a failure. Check the default settings and run the tests
again. If another failure occurs, contact Xycom Automation’s Product Repair & Cus-
tomization Department (see Chapter 5).
Note
Remove any device drivers or memory resident programs (TSRs) in-
stalled on the system before running Xycom Automation diagnostic
tests. If you do not, unexpected failures may occur.
The diagnostic disk does not provide an option to test a CD-ROM drive.
Make sure the BIOS setup menus are configured properly (factory set configuration).
To enter the BIOS setup menus,
1. Press F2 after the POST RAM test has completed.
2. Make the necessary changes by following directions on the screen.
3. Press ESC.
4. Press ENTER twice to save the settings and exit the BIOS setup menus.
Refer to your CPU manual for more information on the BIOS setup menus.
Preparing for the Tests
You need the following equipment to test your system:
•Floppy disk drive
•Xycom Automation System Test Disk (3.5-inch, DS/DD bootable disk, Xycom
Automation part number 99290-001)
•Centronics-compatible printer cable
•Parallel printer (Centronics-style interface)
•Two serial loopback test connectors (refer to Figure 2-12-1 for pinouts)
•Formatted 3.5-inch, DS/HD disk (1.44 MB)
•IBM PC/AT or PS/2 compatible keyboard

3500 Series Flat Panel Industrial PC
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Perform the steps below before starting the system tests:
1. Place the CPU board jumpers and switches to the factory set positions. Refer to your
CPU manual for these settings.
2. Plug the female end of the AC power cable into the side of the unit and the male end
into a properly grounded outlet.
3. Connect the serial loopback connector(s) and the printer cable to the appropriate
connectors and connect a PC/AT or PS/2 keyboard. Figure 2-1 illustrates the wiring
necessary for the loopback connection.
4. Default the CMOS setup to the factory settings.
Figure 2-1. Serial Loopback Connections