Xycom 3600 Series 3612T User manual



2004 XYCOM™ AUTOMATION, INC. Printed in the United States of America
3600 Series
Flat Panel Industrial PCs
User Manual for the
3612T, 3612KPM, 3612KPMT,
3615T, 3615KPM, & 3615KPMT
Models

3600 Series Flat Panel Industrial PC Revision Record
i 142214 (F)
Revision Description Date
A Manual Released 7/03
B Manual updated with KPM features 8/03
C Hazardous Locations Control Drawing 12/03
D Added 3615 information 2/04
E Updated touch screen driver installation and calibration / 5/04
Added TIR caution note / 6/04
F Updated Front Panel table / Updated 3612T frame 8/04
composition information
Part Number 142214(F)
Trademark Information
Brand or product names are trademarks or registered trademarks of their respective owners.
Intel and Pentium are registered trademarks and Celeron is a trademark of Intel Corporation.
Windows, Windows NT, and Windows XP are registered trademarks of Microsoft Corporation in the U.S. and in
other countries.
Copyright Information
This document is copyrighted by Xycom Automation Incorporated (Xycom Automation) and shall not be reproduced
or copied without expressed 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.
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 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 correct the interference at the user’s 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 applying to the legal operation of this device. It is the responsibility of the system integrator
and/or user to apply the following directions relating to installation and configuration:
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.
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.
EMC compliance is, in part, a function of PCB design. Third party add-on AT/XT peripheral PCB assemblies installed
within this apparatus 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 manufactured and/or expressly tested and approved for
compliance by XYCOM AUTOMATION. It is the responsibility of the system integrator/user to ensure that installation
and operation of such devices does not void EMC compliance.

ii 142214 (F)
Table of Contents
CHAPTER 1 – INTRODUCTION...........................................................................................................................1
PRODUCT OVERVIEW................................................................................................................................................1
STANDARD FEATURES ..............................................................................................................................................1
OPTIONAL FEATURES................................................................................................................................................3
Front Panels ........................................................................................................................................................4
I/O Panel .............................................................................................................................................................8
Back Panel.........................................................................................................................................................10
Power Panel ......................................................................................................................................................11
UNPACKING THE SYSTEM .......................................................................................................................................12
QUICK STARTUP .....................................................................................................................................................12
CHAPTER 2 – INSTALLATION ..........................................................................................................................13
INSTALLATION OVERVIEW......................................................................................................................................13
SYSTEM CUTOUT DIMENSIONS ...............................................................................................................................15
3612T................................................................................................................................................................15
3612KPM(T).....................................................................................................................................................16
3615T................................................................................................................................................................17
3615KPM(T).....................................................................................................................................................18
POWER MANAGEMENT ...........................................................................................................................................19
System Power.....................................................................................................................................................19
Excessive Heat...................................................................................................................................................20
Electrical Noise .................................................................................................................................................20
Line Voltage Variation ......................................................................................................................................20
AC Power Cable ................................................................................................................................................21
INSTALLING INTERNAL HARDWARE OPTIONS .........................................................................................................22
DRAM and Additional DRAM Dual Inline Memory Modules (DIMMs) ...........................................................23
PC/AT
™
and PCI Boards...................................................................................................................................23
USING A TOUCH SCREEN ........................................................................................................................................23
Installing the Touch Screen Driver....................................................................................................................23
Calibrating the Touch Screen............................................................................................................................24
CUSTOM LOGO .......................................................................................................................................................25
CREATING CUSTOM KEYPAD INSERTS....................................................................................................................26
HAZARDOUS LOCATIONS INSTALLATION ................................................................................................................30
Safety Agency Approval.....................................................................................................................................31
Definitions .........................................................................................................................................................32
Class I Locations ...............................................................................................................................................32
Class II Locations..............................................................................................................................................32
Division 1 Locations..........................................................................................................................................32
Division 2 Locations..........................................................................................................................................33
Groups...............................................................................................................................................................33
Enclosures .........................................................................................................................................................34
Power Switch.....................................................................................................................................................34
Cable Connections.............................................................................................................................................34
Communication Cable Interfaces ......................................................................................................................35
Hazardous Locations Control Drawing ............................................................................................................36
Operation and Maintenance..............................................................................................................................37
CHAPTER 3 – KEYPAD UTILITY PROGRAM ................................................................................................38
LOADING THE KEYPAD UTILITY..............................................................................................................................38
USING THE KEYPAD UTILITY ..................................................................................................................................39

3600 Series Flat Panel Industrial PC Table of Contents
iii 142214 (F)
STARTUP.................................................................................................................................................................39
MAIN MENU ...........................................................................................................................................................39
Exit.....................................................................................................................................................................40
Files Menu.........................................................................................................................................................40
Macros Menu.....................................................................................................................................................41
Upload Menu.....................................................................................................................................................43
Download Menu ................................................................................................................................................43
Utilities Menu ....................................................................................................................................................44
UTILITY BATCH MODE ...........................................................................................................................................44
KEYPAD SCAN CODES ............................................................................................................................................45
CHAPTER 4 – MAINTENANCE ..........................................................................................................................48
GENERAL PREVENTIVE MAINTENANCE ..................................................................................................................48
Fuse Replacement..............................................................................................................................................48
Fan Filter Replacement.....................................................................................................................................48
RECOMMENDED HARD DRIVE PREVENTIVE MAINTENANCE...................................................................................49
PRODUCT REPAIR PROGRAM ..................................................................................................................................50
FRONT PANEL FRAME.............................................................................................................................................51
Chemicals Compatible with 3612 Frame ..........................................................................................................51
Chemicals Not Compatible with 3612 Frame....................................................................................................51
Chemicals Compatible with 3615Frame ..........................................................................................................52
FRONT PANEL OVERLAY ........................................................................................................................................53
Chemicals Compatible with Overlay .................................................................................................................53
Compatible Cleaning Agents for Overlay..........................................................................................................53
Chemicals Not Compatible with Overlay ..........................................................................................................53
CHAPTER 5 TROUBLESHOOTING...................................................................................................................54
DIAGNOSTIC TESTING.............................................................................................................................................54
Create Diagnostic Disk......................................................................................................................................54
Prepare the System............................................................................................................................................54
RUNNING THE TESTS ..............................................................................................................................................56
MS-DOS
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

Reinstallation ...................................................................................................................................57
Windows  98 Reinstallation .............................................................................................................................57
Windows  2000 Reinstallation.........................................................................................................................58
Windows NT  Reinstallation ............................................................................................................................58
Windows XP® Reinstallation ............................................................................................................................58
INSTALLING DRIVERS .............................................................................................................................................59
Video Drivers.....................................................................................................................................................59
Video Expansion................................................................................................................................................59
Touch Screen Drivers ........................................................................................................................................60
Miscellaneous Drivers.......................................................................................................................................60
APPENDIX A – TECHNICAL SPECIFICATIONS............................................................................................61
HARDWARE SPECIFICATIONS ..................................................................................................................................61
ENVIRONMENTAL SPECIFICATIONS .........................................................................................................................62
APPENDIX B –BLOCK DIAGRAM AND AIM3 LAYOUT..............................................................................63
AC BLOCK MODEL.................................................................................................................................................63
AIM3 CPU BOARD LAYOUT..................................................................................................................................64
APPENDIX C – PINOUTS.....................................................................................................................................65
KEYBOARD PORT CONNECTOR...............................................................................................................................65
MOUSE PORT CONNECTOR .....................................................................................................................................65
DUAL USB CONNECTOR (USB1) ...........................................................................................................................66

3600 Series Flat Panel Industrial PC Table of Contents
iv 142214 (F)
PARALLEL PORT CONNECTOR (LPT1)....................................................................................................................66
SERIAL PORT CONNECTORS....................................................................................................................................67
COM1....................................................................................................................................................................67
COM2....................................................................................................................................................................68
VGA CONNECTOR..................................................................................................................................................68
APPENDIX D – AIM3 CONTROLLER JUMPERS............................................................................................69
APPENDIX E – TSKAM JUMPER AND SWITCH SETTINGS .......................................................................70
TSKAM BOARD 1, PART NUMBER 141438-001 2.................................................................................................70
TSKAM BOARD 2, PART NUMBER 142430-001/2.................................................................................................71

1 142214 (F)
Chapter 1 – Introduction
Product Overview
The 3600 series of flat-panel Industrial PCs combines an Intel
®
Celeron
®
or
Pentium
®
III processor with a flat-panel display to offer a powerful, compact
package for the factory floor and other harsh environments. These PCs feature an
open architecture to meet a wide variety of applications that require both a
powerful PC and a durable industrial enclosure. The system integrates a computer
card cage, mass storage, display, and power supply in a reliable industrial form
factor.
The 3612T and 3615T are Industrial PCs with touch screen displays. The
3612KPM and 3615KPM are Industrial PCs with displays, integrated keypads and
integrated mouses. The 3612KPMT and 3615KPMT are Industrial PCs with
integrated keypads, integrated mouses, and touch screen displays.
A 3600 system includes:
•
••
• A four-slot ISA/PCI backplane, which accommodates
- three ¾ length expansion cards: one PCI, one ISA, & one PCI or ISA
- one ½ length PCI card.
•
••
• Flat panel display
3612 – 12.1” – 800x600 SVGA (TFT)
3615 – 15” – 1024x768 XGA (TFT)
The front panel of the unit is sealed to NEMA TYPE 4/4X/12 (UL 50) and IP65
(IEC 60529) standards and is protected by an impact-resistant shield.
The processor board combines all the functions of a complete PC/AT compatible
computer on a single industrially hardened circuit board. Refer to the AIM3 CPU
manual for more information on processor and hardware features.
The system’s modular design allows easy access to expansion boards, switches,
power supply, flat-panel display, and disk drives.
Standard Features
The 3600 unit comes standard with the following:
•
••
• AIM3 CPU Board
•
••
• Two serial COM ports, with one configured as RS-232 and one configurable as
either RS-232 or RS-485
•
••
• Parallel port
•
••
• VGA port

3600 Series Flat Panel Industrial PC Chapter 1 – Introduction
2 142214 (F)
•
••
• Intel
®
Socket 370 Celeron
®
or Pentium
®
III options up to 1.26GHz
•
••
• AGP video controller, 4 MB system video RAM, up to 32 MB available
•
••
• PCI local-bus IDE controller
•
••
• Two 168-pin SDRAM DIMMs that support 128, 256, and 512 MB options
•
••
• Two USB 1.1 ports
•
••
• 100MHz or 133MHz front side bus depending on the Celeron or Pentium III
processor type
•
••
• Standard Features of a 3600 Unit
•
••
• Flash BIOS
•
••
• 6.42" mounting depth (maximum for all 3600 models)
•
••
• Flat-panel active color TFT display:
• 12.1" (800x600) on 3612s
• 15" (1024x768) on 3615s
•
••
• Four AT bus expansion slots
• One ½ length PCI
• One ¾ length ISA
• One ¾ length PCI
• One ¾ length PCI slot or ISA slot
•
••
• Rear IBM
®
PS/2
®
keyboard port and mouse port
•
••
• Status LEDs
• Power
• Disk
• COM
• Input
• Fault
•
••
• Floppy drive, rear access
•
••
• CD-ROM, rear access
•
••
• Removable 20 GB hard drive, rear access
•
••
• MS-DOS
®
operating system
•
••
• All 3600 front panels meet NEMA 4/4X/12 and IP65 specifications when panel-
mounted
•
••
• UL Listed for use in Class I and Class II, Division 2 hazardous locations, Groups
A, B, C, D, F, and G

3600 Series Flat Panel Industrial PC Chapter 1 – Introduction
3 142214 (F)
Additional standard features 3612KPM(T) & 3615KPM(T) models
•
••
• 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
•
••
• Nonincendive front panel USB and PS/2 keyboard/mouse ports
Optional Features
Following are optional available features:
•
••
• Touch screen resistive technology
•
••
• Higher capacity IDE hard drives and solid state drives
•
••
• Various processor speeds
•
••
• Preinstalled Microsoft
®
Windows
®
98, or Windows NT
®
, or Windows
®
2000, or
Windows XP
®
Professional
•
••
• Compact Flash
•
••
• 2.5” Dual Hard Drive
•
••
• 9000-USBF, USB floppy (requires Windows 98, 2000, or XP)
•
••
• 9000-USBFKA, front access NEMA-sealed USB floppy and keyboard port
(requires Windows 98, 2000, or XP)
•
••
• 9000-RF1, 19” Rack Mount Adapter Plate (for 3612T)
•
••
• 9000-XBAY (requires an XBAY connector)
•
••
• 9000-CAP-3612KPM/9487 Adapter Plate (for 3612KPM) to mount in a 9487 or
9450 cutout

3600 Series Flat Panel Industrial PC Chapter 1 – Introduction
4 142214 (F)

The 3600 series has a NEMA 4/4X/12 and IP65 sealed front panel. The panel
protects the system’s interior when the system is properly panel-mounted.
3612T & 3615T Front Panel
Figure 1-1. 3612T Front Panel

3600 Series Flat Panel Industrial PC Chapter 1 – Introduction
5 142214 (F)
Table 1-1. 3612/15T Front Panel
Feature Description
Front Panel The front panel has four components: a display; strengthened
glass covering the display; a frame in which the display and the
glass are mounted; and the polyester overlay attached to both
the glass and the frame.
The 3612T has a 12.1" TFT LCD flat panel. The 3615T has a
15" TFT LCD flat panel.
The strengthened glass covering the display is intended to
withstand normal operating conditions. In the event of damage
to the glass, the overlay will protect the user from any glass
shards.
For more information abut the frame or the overlay, see
Chapter 5 – Troubleshooting.
Diagnostic LEDs Following is a description of the LEDs and their meanings:
Power GREEN when the system has power.
Disk GREEN when the computer is accessing the disk drive.
COM GREEN when there is communication activity on one
of the serial ports.
Input GREEN when the unit has a touch screen (LED gets
brighter when a touch input is detected) or a key is
pressed.
Fault YELLOW when a configuration error exists.
During power-up, the BIOS checks the hardware configuration
against the configuration stored in the CMOS memory.
Brightness
Adjustment These buttons adjust the brightness of the backlights. The right button increases the brightness and the left button decreases
the brightness.