Xycom 9450 User manual

9450
Industrial PC/AT™
Computer System
P/N 99446-001E
 1997 XYCOM, INC. Printed in the United States of America

Xycom Revision Record
Revision Description Date
AManual Released 5/94
BManual Updated 7/95
CManual Update (incorporated PCN #188) 1/96
DManual Updated 5/96
EManual Updated 10/97
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
Technical Publications Department
750 North Maple Road
Saline, MI 48176–1292
[phone] (phone)
[phone] (fax)

Table of Contents
Chapter 1– Introduction..................................................................................................................1-1
Product Overview...........................................................................................................................1-1
Standard Features.........................................................................................................................1-2
Optional Features..........................................................................................................................1-2
Unpacking the System ..................................................................................................................1-3
Quick Start-Up..............................................................................................................................1-3
Chapter 2– Testing.........................................................................................................................2-1
Introduction...................................................................................................................................2-1
Checking System Setup................................................................................................................2-1
Phoenix BIOS ...........................................................................................................................2-1
Quadtel BIOS............................................................................................................................2-2
Initiating the Tests.........................................................................................................................2-2
Preparing for the Tests...................................................................................................................2-2
Running the Tests.........................................................................................................................2-3
Chapter 3– Installation...................................................................................................................3-1
System Components.....................................................................................................................3-1
Front Panel...............................................................................................................................3-1
Back Panel...............................................................................................................................3-4
Preparing the System for Use.........................................................................................................3-6
Installing/Removing the Slide-Out Computer Module.........................................................................3-7
Removing the Slide-Out Computer Module ...................................................................................3-8
Re-installing the Slide-Out Computer Module................................................................................3-8
Installing Internal Hardware Options ................................................................................................3-9
Installation and Removal of the CPU Board...................................................................................3-9
Installing the RADAR Card........................................................................................................ 3-11
Installing PC Boards ................................................................................................................ 3-12
Installing External Hardware Options............................................................................................. 3-13
Keyboards .............................................................................................................................. 3-13
Serial Mouse........................................................................................................................... 3-14
Installing Operating Systems........................................................................................................ 3-15
Installing the 8x14 Font TSR........................................................................................................ 3-15
Installing Drivers.......................................................................................................................... 3-15
Video Drivers........................................................................................................................... 3-15
Mouse Drivers ......................................................................................................................... 3-15
Touch Screen Drivers ............................................................................................................... 3-16
Miscellaneous Drivers .............................................................................................................. 3-16
Installing the Serial Port FIFO Control ........................................................................................... 3-16

Xycom Revision Record
Installing the System into a Panel................................................................................................. 3-17
Mounting Considerations .......................................................................................................... 3-17
System Power......................................................................................................................... 3-18
Heat ....................................................................................................................................... 3-18
Excessive Noise...................................................................................................................... 3-19
Excessive Line Voltage............................................................................................................ 3-19
Mounting the 9450................................................................................................................... 3-19
Available Power........................................................................................................................... 3-20
Chapter 4– Programmable Keypad Interface Module Utility..........................................................4-1
Loading the PKIM Utility ................................................................................................................4-1
Using the Programmable Keypad Utility ..........................................................................................4-1
Startup .....................................................................................................................................4-2
Utility Batch Mode.....................................................................................................................4-2
Main Menu ...................................................................................................................................4-3
Exit..........................................................................................................................................4-3
Files Menu................................................................................................................................4-3
Macros Menu............................................................................................................................4-4
Upload Menu.............................................................................................................................4-6
Download Menu.........................................................................................................................4-7
Utilities Menu............................................................................................................................4-7
Codes ..........................................................................................................................................4-8
Chapter 5 – Maintenance ...............................................................................................................5-1
Preventive Maintenance.................................................................................................................5-1
Replacing the External Battery .......................................................................................................5-2
Spare Parts List............................................................................................................................5-2
Product Repair Program/Returning a Unit to Xycom..........................................................................5-3
Preparing the Unit for Shipment...................................................................................................5-3
Appendix A – Technical Specifications..........................................................................................A-1
Hardware Specifications.................................................................................................................A-1
Environmental Specifications..........................................................................................................A-2
Regulatory Compliance..................................................................................................................A-2
Appendix B – Block Diagrams/Dimensions/ Inserts........................................................................B-1
Appendix C – Pinouts.....................................................................................................................C-1
COM1/COM2 Serial Port Connectors ..............................................................................................C-1
VGA Connector.............................................................................................................................C-1
Parallel Port Connector (LPT1) .......................................................................................................C-2
Keyboard Connectors ....................................................................................................................C-2
Speaker Jack................................................................................................................................C-3

1-1
Chapter 1 – Introduction
Product Overview
The 9450 Industrial Computer System puts the power and versatility of an IBM
PC/AT™-compatible computer in a package that makes sense for the factory floor and
other harsh environments. The Xycom 9450 Industrial PC/AT Computer System features
an open architecture to meet a variety of applications that require both a powerful PC and
a durable industrial enclosure. The system integrates a computer card cage, mass storage,
display, keypads, and power supply in a truly industrial form factor.
The 9450 system includes a seven-slot passive backplane, an SVGA monitor, hard and
floppy disk drive facilities, and data entry and function keypads. The front panel is sealed
to NEMA 4/NEMA 12 standards, and the CRT is protected with an impact-resistant
Lexan shield. The open-architecture design accepts IBM PC-, XT-, or AT-compatible
cards.
The system comes with a 486, 5x86, or Pentium® computer installed (configuration de-
termined upon order). The processor board combines all the functions of a complete IBM
PC/AT-compatible computer on a single, industrially-hardened circuit board.
The system’s “works in a module” design allows easy access to the boards, switches,
power supply and disk drives. The module is easily removed by loosening three thumb
screws and sliding the module out.
The 9450 supports a variety of industrial software packages including the following:
•SoftScreen PC/AT
•6200
•Aimax-Plus
•CELLworks
•CITECT
•Control View*
•Direct Factory
•Fix/DMACS
•Factory Link
•FloPro
•Genesis
•Intouch
•ModSoft
•OI-2000
•Paragon 500*
•PCIM
•Screen Ware2
•Viewpoint
The software list is continually expanding. Consult Xycom for additional listings.

9450 Industrial PC/AT Computer System
1-2
*Note
The 8x14 character font set has been removed from the Quadtel BIOS used on the
AT4+ CPU board. This font set is now emulated to support most applications. If your
application does not display 8x14 characters correctly, install the TSRFONT.COM
file. See Chapter 3 for installation instructions.
Standard Features
The 9450 offers the following standard features:
•486, 5x86, or Pentium CPU
•Seven-slot PC/AT passive backplane (four full length, two half length, and one ¾
length AT slots); Six slots available on 486 configuration; Five slots available on
Pentium configuration
•14" high-resolution SVGA color monitor
•32 data-entry and 20 function keys
•IDE hard disk
•MS-DOS®
•Slide-out computer module
•150-watt power supply
•IBM PC/AT/XT compatibility
•External printer port
•External COM1 and COM2 ports
•Rugged front panel sealed to meet both NEMA 4/NEMA 12 specifications when
panel-mounted
Optional Features
The following optional items are also available with the 9450:
•Solid State FLASH drives
•Larger hard disk drives
•Touch Screen
•SoftScreen operator interface software
•External full-stroke keyboard (4100-KB2)
•RADAR card with isolated RS-232C/RS-485 serial ports (9000-RAD)
•Various sealed rack- or panel-mount keyboards (8000-KBX)

Chapter 1 – Introduction
1-3
•Microsoft®Windows®3.11 (4100-WIN)
•Pre-installed Microsoft Windows 95 or Windows NT™ operating systems
•Built-in mouse
Unpacking the System
When you remove the 9450 from its shipping carton, verify that you have the parts listed
below. Save the box and inner wrapping in case you need to reship the unit.
•9450 unit
•Miscellaneous Accessories and documentation kit, which includes:
•Documentation for the operating system that has been pre-installed
•Power cable
•Diagnostic software disk
•16 nuts
•9450 user manual
•CPU manual
•Business reply card
•Video driver disk
If you ordered the system with SoftScreen installed, the documentation kit will include the
following:
•SoftScreen Runtime System disks
•Software protection key
•SoftScreen Runtime Engine manual
•Registration card
If you ordered the system with a touch screen installed, you will also receive a touch
screen driver disk and manual.
Quick Start-Up
Warning
Turn off power to the unit and unplug the power cord before making any adjustments
to the inside or outside of the computer.
Warning
If the battery is disabled, when it is re-enabled the system must be powered up for a
minimum of 30 seconds. Failure to follow this procedure may result in premature bat-
tery failure.

9450 Industrial PC/AT Computer System
1-4
Note
If a touch screen has been factory installed, there is an AT adapter board plugged into
the backplane in slot 5. Connect the 9-pin cable from the monitor side to the 9-pin con-
nector in slot 5.
To prepare the system for use, perform the following steps.
1. Connect the video cable to the 15-pin connector on the CPU board.
2. Connect the PWR/Key 15-pin cable to the PWR/Key female receptacle located
above the power receptacle.
3. Attach the power cord from the monitor to the power receptacle. Attach the power
cord power receptacle to a properly grounded 115/230 VAC, 50/60 Hz outlet. Attach
the power cord to the lower power receptacle.
4. Connect the 9-pin DB connector which is attached to the touch screen adapter board
located in slot 5 (optional feature).
5. Turn on power to the unit by pressing the ON/OFF switch. The system will boot up at
the C: prompt if MS-DOS is properly installed on drive C.
6. Set the contrast and brightness controls on the back panel to the desired levels.
7. Install the application software via drive A, located behind the access door on the
front panel.

Chapter 2 - Testing
2-1
Chapter 2 – Testing
Introduction
Diagnostic tests are provided to verify operation of 9450 system hardware functions. If
any of these tests fail, either you do not have the correct default setting or there is a sys-
tem failure. Check the default settings and run the tests again. If there is a failure, contact
Xycom’s Product Repair & Customization (PR&C) Department (see Chapter 5).
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
diagnostics tests.
Checking System Setup
You want to ensure that the Setup Menu is configured properly (factory-set configura-
tion). The way you access the Setup Menu depends on the CPU board installed in your
system.
Phoenix BIOS
If the CPU board has a Phoenix BIOS, press F2 when prompted to enter the Setup Menu.
Make the necessary changes by following the on-screen directions. General instructions
for navigating through the Setup screens are described below:
•ÅÆ select a menu. Once you’ve selected a menu, press ENTER to validate your se-
lection.
•ÇÈ select an item in the menu. Once you’ve selected an item, press ENTER to vali-
date your selection.
•ESC exits the menu. You are prompted to save changes.
•+/- change values.
•ENTER selects a sub-menu.
•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.

9450 Industrial PC/AT Computer System
2-2
Quadtel BIOS
If the CPU board has a Quadtel BIOS, press CTRL+ALT+S simultaneously to access the
Setup Menu. Follow the on-screen directions to make changes. Press F10 to save
changes, and ESC to exit. Refer to the CPU manual for more information on the Setup
Menu.
Initiating the Tests
You need the following equipment to test your system:
•Xycom System Test Disk – 3.5-inch, DS/HD disk (bootable)
•IBM PC/AT-compatible keyboard
•Centronics-compatible printer cable
•Parallel printer (Centronics-style interface)
•Two serial loopback test connectors (refer to Figure 2-1 for pinout)
•Scratch disk formatted 3.5 -inch, DS/HD (1.44 Mbyte)
Preparing for the Tests
Perform the steps below before starting the system test:
1. Place the CPU board jumpers and switches to the factory set positions. The numbers
in parenthesis are the pins onto which to install the jumper, (e.g. J1 (3-4) indicates
the jumper is on pins 3 and 4 of J1). Refer to your CPU manual for jumper and
switch settings.
2. Plug the female end of the AC power cable into the rear of the unit and the male end
into a properly grounded outlet.
3. Connect the video cable to the 15-pin connector on the CPU board.
4. Connect the PWR/key 15-pin cable to the Pwr/key female receptacle located above
the power receptacle.
5. Attach the monitor power cord from the monitor to the power receptacle
6. Connect the serial loopback connector(s) and the printer cable to the appropriate
connectors and connect a PC/AT-compatible keyboard to a keyboard connector. Fig-
ure 2-1 illustrates the wiring necessary for the loopback connection.

Chapter 2 - Testing
2-3
Figure 2-1. Serial Loopback Connections
Running the Tests
To run the test, insert the diagnostics disk into drive A. Turn on the computer (the diag-
nostics program will boot up). Figure 2-2 shows the Main Menu as it is displayed on the
screen.
Copyright 1990-1994, Xycom, Inc. All rights reserved.
Diagnostic Tests Sequence/Selection Menu (Rel. xx)
0) WILL pause on an error 4) Auto-select tests
1) SINGLE PASS test mode 5) Deselect all tests
2) Save setup to file 6) Quit and exit to DOS
3) Extract setup from a file 7) Return to Previous screen
A) RAM Test K) Video Interface Test
B) Video RAM Test L) Speaker Port Test
C) Extended RAM Test M) LPT1: Printer Port Test
D) Real Time Clock Test N) LPT2: Printer Port Test
E) COM1 Serial Port Test O) C: Hard Drive Interface Test
F) COM2 Serial Port Test P) D: Hard Drive Interface Test
G) COM3 Serial Port Test Q) A: Floppy Drive Interface Test
H) COM4 Serial Port Test R) B: Floppy Drive Interface Test
I) Math Coprocessor Test S) Keyboard, Keypad Tests
J) Video Adjustments Test ≡= Test Selected
[ENTER] = START TESTING
Use the letters to move the cursor and select/deselect, or use the arrow keys
to move, then use the [SPACE] key to select/deselect a test or function:
Figure 2-2. Main Menu
You can select tests individually. However, we recommend you use Auto-select (4)
which will select all the tests appropriate to your configurations.

9450 Industrial PC/AT Computer System
2-4
Note
Please read the DIAG.TXT and CMOS.TXT files on the diagnostics disk for detailed
information.
Warning
If your system has a solid state (Flash) drive installed, avoid repeated running of op-
tion O, the hard drive interface test. The Flash drive has a limited number of writes to
each logical sector. Repeated writes from the diagnostic utility will prematurely
shorten the life of the drive.

Chapter 2 - Testing
1
Chapter 3 – Installation
This chapter contains an overview of the 9450 hardware and I/O locations, as well as in-
stall options.
System Components
This section describes the 9450’s front and back panel components to familiarize you
with the system.
Front Panel
The 9450 comes equipped with a NEMA 4/NEMA12 sealed front panel. The panel pro-
tects the system’s interior when the system is properly panel mounted. Figure 3-1 illus-
trates the front panel features of the 9450.
Figure Chapter 3 -1. 9450 Front Panel

9450 Industrial PC/AT Computer System
2
Monitor Protected from breakage by an impact-resistant Lexan shield,
the 14" monitor supports a high resolution SVGA color. If the
touch screen option is installed, the Lexan shield will be re-
placed by a safety-glass backed touch panel.
Function Keys These 20 keys provide easy access to familiar PC routines. The
programmable keys allow you to customize your keycodes.
These keys are located directly below the monitor.
Access Door Located below the data entry keypad, this door allows access to
the floppy disk drive and the keyboard port. The keyboard port
allows a PC/AT keyboard to be interfaced with the system.
Data Entry Keypad This 32-key numeric keypad includes the 15 data entry keys,
the up, down, left, and right arrows; and numbers 0-9. All keys
on the keypad are programmable and the top 15 are relegend-
able.
System Status LEDs During power-up, the CPU board checks its hardware configu-
ration against the configuration information stored in CMOS
memory. If the power-up-self-test (POST) is successful, the
MAINT and FAULT LEDs will be off. If the 9000-RAD card
is installed and any of the RADAR features are enabled, the
RADAR LED will turn on.
Diagnostic LEDs Power indicates that +5VDC is present. Disk indicates hard
disk activity when on or flashing. COM indicates COM1 or
COM2 port activity when on or flashing. RADAR indicates Run
Time Diagnostics are enabled. Table Chapter 3 -1 indicates the
condition of your system based on system status LEDs.
Table Chapter 3 -1. System Status LEDs
Fault Maint Power Radar Condition
off off off off No power
off off on off System in reset prior to POST
off on on off Running POST
on off on off Failed POST
off off on off Passed POST (RADAR off)
off off on on Passed POST (RADAR on)
off on on on *RADAR Maintenance
on off on on *RADAR Fault
*Must have 9000-RAD installed for these features to be available.

Chapter 2 - Testing
3
Note
486 CPU boards are installed in Slot 0, and Pentium CPU boards are installed in Slot 1
to accommodate the heat sink.

9450 Industrial PC/AT Computer System
4
Back Panel
Figure Chapter 3 -2 illustrates the 9450’s back panel components.
Figure Chapter 3 -2. 9450 Back Panel Components
ON/OFF Switch Place this switch in the OFF position (switch should be
out) until the system is properly configured and con-
nected to a 115 VAC or 230 VAC power source.
Power Receptacle The power receptacle is located to the right of the
ON/OFF switch. The upper power outlet is for the
monitor and the lower power outlet is for the main
power source. The plug and cord for the AC power and
the monitor power must be securely positioned before
turning power on.
Video Connector The 15-pin high density video cable is connected to the
VGA port on the CPU.
Video Controls The contrast and brightness controls are located on the
right hand side of the unit. Turning the knobs left or
right will adjust contrast or brightness on the monitor.
The vertical size, horizontal position and vertical posi-
tion are located above the contrast and brightness con-
trols. Turning the knobs left or right will adjust the ver-
tical position, horizontal position, and vertical height.

Chapter 2 - Testing
5
Parallel Port The parallel port connector is a DB-25 female and is
located on the CPU board for all configurations. The
pinouts for connectors and ports are shown in Appendix
C.
PWR/Key This 15-pin dual row DB connector provides the power,
keyboard and LED signals to the front keypad controller
board.
COM1/COM2 Ports These serial ports are RS-232 and use DB-9 male con-
nectors. The optional built-in mouse uses the COM2
port.
External Battery The 9450 has an external battery located to the right of
the PWR/Key connector.
Rear Keyboard Connector There is a PC/AT keyboard connector on the rear of the
9450. Both front and rear keyboards can be connected
simultaneously.
Touch Screen Cable The optional touch screen cable has a 9-pin DB con-
nector which is attached to the connector on the touch
screen adapter board located in Slot 5.
Figure Chapter 3 -3. Internal System Components

9450 Industrial PC/AT Computer System
6
Preparing the System for Use
To prepare the system for use, perform the steps listed below. If you purchased any op-
tions, install them according to the instructions in the next two sections.
1. Connect the video cable to the 15-pin connector on the CPU board.
2. Connect the PWR/Key 15-pin cable to the PWR/Key female receptacle located
above the power receptacle.
3. Attach the power cord from the monitor to the power receptacle. Attach the power
cord power receptacle to a properly grounded 115/230 VAC, 50/60 Hz outlet. Attach
the power cord to the lower power receptacle.
4. Connect the touch screen.
Note
If a touch screen has been factory installed, there is an AT adapter board plugged into
the backplane in slot 5. Connect the 9-pin cable from the monitor side to the 9-pin con-
nector in slot 5.
6. Press the ON/OFF switch to turn on power to the unit. The system will boot up at the
C: prompt if MS-DOS is properly installed on drive C.
7. Set the contrast and brightness controls on the back panel to the desired levels.
8. Install the application software via drive A located behind the access door on the
front panel.
Note
The 8x14 character font set has been removed from the Quadtel BIOS used on the
AT4+ CPU board. This font set is now emulated to support most applications. If your
application does not display 8x14 characters correctly, install the TSRFONT.COM file.

Chapter 2 - Testing
7
Installing/Removing the Slide-Out Computer Module
The slide-out computer module (shown in Figure Chapter 3 -4) allows access to the
power supply and disk drives. The PC add-in boards can be replaced by removing the
three screws on the hinged top cover.
Figure Chapter 3 -4. Installing the Slide-out Computer Module

9450 Industrial PC/AT Computer System
8
Removing the Slide-Out Computer Module
Figure Chapter 3 -5 shows removal of the slide-out computer module.
Figure Chapter 3 -5. Removing the Slide-Out Computer Module
Follow the steps below to remove your slide-out computer module.
1. Disconnect cables (VGA, PWR/Key, Power, and optional touch screen).
2. Loosen the three thumb screws that attach the slide-out computer module to the 9450
back panel.
3. Grasp the handle that protrudes from the back panel.
4. Pull straight back. The module should slide out easily.
Note
Place a hand underneath to support weight of module.
Re-installing the Slide-Out Computer Module
After you have finished installing options on your 9450, reconnect it to the front panel
according to the following instructions: