Xycom 3510T User manual

3500 3-Slot Manual
3510T/3510KP(T), 3512T/3512KP(T), 3535T/3535KPM(T) Flat-Panel Industrial PCs


2002 XYCOM AUTOMATION, INC. Printed in the United States of America

Revision Record
3
Revision Description Date
A Manual Released 5/99
B Updated Specifications 7/99
C Updated Bulb Replacement/CD-ROM Floppy addition 5/01
D Addition of 3535 Flat Panel Monitor PC 3/02
E Touchscreen Updates 7/02
Part Number 350003(E)
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 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 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 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.

Table of Contents
5
CHAPTER 1 - INTRODUCTION..............................................................................................................................9
PRODUCT OVERVIEW..................................................................................................................................................9
Standard Features .................................................................................................................................................9
Optional Features (All Units)..............................................................................................................................11
UNPACKING THE SYSTEM .........................................................................................................................................11
QUICK START-UP......................................................................................................................................................12
CHAPTER 2 - TESTING..........................................................................................................................................13
PREPARING FOR THE TESTS ......................................................................................................................................13
RUNNING THE TESTS ................................................................................................................................................15
CHAPTER 3 – INSTALLATION ............................................................................................................................17
FRONT PANEL...........................................................................................................................................................17
3510T/12T Front Panel.......................................................................................................................................17
3510KP/3512KP and 3510KPT/3512KPT Front Panel......................................................................................19
3535T Front Panel ..............................................................................................................................................21
3535KPM(T) Front Panel....................................................................................................................................22
I/O Panel 3510/1512 ...........................................................................................................................................23
I/O Panel 3535 ....................................................................................................................................................23
Back Panel...........................................................................................................................................................25
Power Panel ........................................................................................................................................................27
Preparing the System...........................................................................................................................................27
INSTALLING INTERNAL HARDWARE OPTIONS ...........................................................................................................28
DRAM and Additional DRAM Single In-line Memory Modules (SIMMs)...........................................................28
PC/AT and PCI Boards .......................................................................................................................................28
INSTALLING EXTERNAL HARDWARE OPTIONS ..........................................................................................................29
9000-EXF External Floppy Drive .......................................................................................................................29
9000-FFK External Front Floppy and Keyboard Access Kit..............................................................................29
9000-CDK External Front Access CD-ROM and Keyboard Kit.........................................................................31
CUSTOM LOGO .........................................................................................................................................................34
CREATING CUSTOM KEYPAD INSERTS (FOR 3510/3512KP UNITS)...........................................................................35
REINSTALLING OPERATING SYSTEMS .......................................................................................................................39
MS-DOS
 reinstallation.....................................................................................................................................39
Windows
 95 reinstallation................................................................................................................................40
Windows
 98 reinstallation................................................................................................................................40
Windows NT
 reinstallation...............................................................................................................................40
Windows
 2000 reinstallation............................................................................................................................41
INSTALLING DRIVERS ...............................................................................................................................................41
Ethernet Drivers ..................................................................................................................................................41
Video Expansion..................................................................................................................................................42
Touchscreen Drivers............................................................................................................................................44
Miscellaneous Drivers.........................................................................................................................................44
USING A TOUCHSCREEN ...........................................................................................................................................45
Calibrating the Touchscreen ...............................................................................................................................47
INSTALLING THE SYSTEM INTO A PANEL...................................................................................................................48
Mounting Considerations ....................................................................................................................................48
SYSTEM POWER........................................................................................................................................................49
EXCESSIVE HEAT......................................................................................................................................................49
ELECTRICAL NOISE...................................................................................................................................................49
LINE VOLTAGE VARIATION.......................................................................................................................................51
CREATING A POWER CABLE......................................................................................................................................51
AC Power Cable..................................................................................................................................................51
DC Power Cable..................................................................................................................................................52

3500 Flat Panel Industrial PCs
6
MOUNTING THE UNIT ...............................................................................................................................................53
System Cutout Dimensions ..................................................................................................................................54
POWER SUPPLY ........................................................................................................................................................56
HAZARDOUS LOCATIONS INSTALLATIONS ................................................................................................................57
SAFETY AGENCY APPROVAL ....................................................................................................................................57
Definitions ...........................................................................................................................................................59
Class I Locations.................................................................................................................................................59
Class II Locations................................................................................................................................................59
Division 1 Locations............................................................................................................................................59
Division 2 Locations............................................................................................................................................60
Hazardous Locations Group Ratings ..................................................................................................................60
ENCLOSURES ............................................................................................................................................................60
POWER SWITCH ........................................................................................................................................................61
CABLE CONNECTIONS...............................................................................................................................................61
Communication Cable Interface..........................................................................................................................61
OPERATION AND MAINTENANCE ..............................................................................................................................62
CHAPTER 4 - KEYPAD UTILITY FOR 3510KP/3512KPM...............................................................................63
LOADING THE KEYPAD UTILITY................................................................................................................................63
USING THE KEYPAD UTILITY ....................................................................................................................................63
CHAPTER 5 - KEYPAD UTILITY FOR THE 3535 KPM...................................................................................73
CHAPTER 6 - MAINTENANCE.............................................................................................................................81
PREVENTIVE MAINTENANCE ....................................................................................................................................81
MAINTENANCE .........................................................................................................................................................82
Fuse Replacement................................................................................................................................................82
Fan Filter Replacement.......................................................................................................................................82
CHEMICAL COMPATIBILITY.......................................................................................................................................83
Compatible Lubricants ........................................................................................................................................84
Compatible Cleaning Agents...............................................................................................................................85
Non-compatible Cleaning Agents........................................................................................................................86
3510/3512/3510KP/3512KP/3535KPM/3535T SPARE PARTS LIST ........................................................................86
PRODUCT REPAIR PROGRAM/RETURNING A UNIT TO XYCOM AUTOMATION............................................................87
APPENDIX A – TECHNICAL SPECIFICATIONS..............................................................................................89
HARDWARE SPECIFICATIONS ....................................................................................................................................89
APPENDIX B - BLOCK DIAGRAM .....................................................................................................................91
APPENDIX C - PINOUTS.......................................................................................................................................93
KEYBOARD PORT CONNECTORS...............................................................................................................................93
AUX PORT CONNECTOR............................................................................................................................................93
DUAL USB CONNECTOR (USB1).............................................................................................................................94
PARALLEL PORT CONNECTOR (LPT1)......................................................................................................................94
SERIAL PORT CONNECTORS......................................................................................................................................94
COM1......................................................................................................................................................................95
COM2......................................................................................................................................................................95
VGA CONNECTOR....................................................................................................................................................96
EXTERNAL FLOPPY CONNECTOR ..............................................................................................................................96
APPENDIX D – REPLACING FLAT PANEL DISPLAY BULBS.......................................................................97
3510 UNITS ..............................................................................................................................................................97
Mitsubishi TFT Flat panel Display (model #AA104VB02)..................................................................................97
3512 AND 3512 KP UNITS........................................................................................................................................99

Table of Contents
7
Mitsubishi TFT Flat panel Display (Model #AA121SK12) .................................................................................99
INDEX.....................................................................................................................................................................103

Chapter One - Introduction
9
Chapter 1 - Introduction
Product Overview
The 3500 series Flat-Panel Industrial Computers combine 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. The PC features an open
architecture to meet a wide variety of applications that require both a powerful PC
and a durable industrial enclosure.
The 3500 systems include:
•A three-slot ISA/PCI backplane which accommodates ¾ length expansion cards
•Flat panel displays
•3510 – 10.4” – 640x480 VGA (TFT)
•3512 – 12.1” – 800x600 SVGA (TFT)
•3535 – 15” – 1024x768 XGA (TFT)
•Touchscreen versions 3510T/3512T/3535T
•Keypad version (3510KP/3512KP/3535KPM)
•Keypad and touchscreen units (3510KPT/3512KPT/3535KPMT)
•Hard disk drive facilities
The front panel of the unit is sealed to NEMA 4/4X/12 and IP65 standards, and is
protected by an impact-resistant shield.
The system’s modular design allows easy access to expansion boards, switches,
power supply, flat-panel display, and disk drives.
Standard Features
The 3500 3-slot series ships standard with the following:
•IntelCeleronor PentiumIII processor
•Up to 512 MB DRAM
•10 GB hard drive
•2 Serial ports
•1 RS-232 or RS-485 port
•1 Dedicated RS-232
•Reprogrammable keypad or analog resistive touchscreen, or both for operator input
•Two USB ports

3500 Flat Panel Industrial PCs
10
•IP65 standard
•UL listed for hazardous locations: Class I, Division 2
•Power supply
•MS-DOSoperating system
•Flash BIOS
•5.75” mounting depth (6.5” with external floppy option, 7.16” with external CD-
ROM/floppy drive option)
•External floppy connector
•Flat-panel display
•10.4” TFT (640x480) (3510)
•12.1” TFT (800x600) (3512)
•Three AT bus ¾ length expansion slots
•One ISA slots
•One PCI slot
•One ISA/PCI slot
•IR Port (IrDA, HPSIR, AND ASKIR compatible)
•Rear PS/2 keyboard port and mouse port (also front PS/2 keyboard port on 3510KP
and 3512KP)
•Keypads (3510KP/3512KP)
•32 relegendable function keys (64 with the F/A function)
•Keypad (3535KPM)
•74-position keypad and industrial mouse (touchscreen option)
•40 relegendable keys (80 with F/A key)
•Status LEDs
•Power
•Disk
•Com
•Input
•External floppy and CD-ROM option, side access
•MS-DOSWindows95, Windows98, Windows NTor Windows2000
•Front panel sealed to meet NEMA 4/4X/12 and IP65 specifications when panel
mounted
•Status LEDs

Chapter One - Introduction
11
•Power
•Disk
•Com
•Input
Optional Features (All Units)
Following are optional available features:
•Faster processor speeds
•Touchscreen-resistive technology with less than 1.5% linearity error
•Preinstalled Windows95, Windows98, Windows2000 or Windows NT
•9000-EXF, hot installable external floppy drive
•9000-RF1 19-inch Rack Mount Adapter Plate (3510, 3512)
•9000-FFK, NEMA 4 Front Floppy Kit
•9000-RFC 19-inch Floppy Door Plate
•2005-RMA 19 inch Rack Mount Adapter Plate (3510KP, 3512KP)
•9000-CDK, NEMA 4 front Access CD-ROM and keyboard kit
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.
•3510T/3512T/3535T or Keypad version
•Documentation kit, which includes:
•Power connector
•Diagnostic software diskette
•14 10-32 hex nuts (2 spares)
•Clip-on Ferrite for mouse cables
•Cable clamp and screw (for strain relief of power cord)
•3510/3512/3535 manual
•CPU manual (CD-ROM)
•Utility diskettes
If you ordered the system with a touchscreen installed, you will also receive a
touchscreen driver diskette and a documentation CD that includes the manual.

3500 Flat Panel Industrial PCs
12
Quick Start-up
This section gives you the steps to get the system up and running without explaining
the capabilities and options.
Warning
Turn off power to the unit and disconnect the power cord before making any
adjustments to the inside or outside of the computer.
To prepare the system for use, perform the following steps.
1. Attach 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 24 VDC outlet, whichever applies. (See Chapter 3,
Creating a Power Cable.)
4. Turn on the power to the unit. The system will boot up into the operating system.
5. Install application software via the external floppy, the network, or the IR port.

Chapter Two - Testing
13
Chapter 2 - Testing
On units with MS-DOS, Xycom Automation provides diagnostic tests to verify the
operation of the system hardware 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 another failure occurs, contact Xycom Automation’s
Product Repair & Customization Department (see Chapter 5).
Note
Remove device drivers and memory resident programs (TSRs) that are installed on the
system before running Xycom diagnostics. If this step is not completed unexpected
failures may occur.
Make sure the BIOS setup menus are configured properly (factory-set configuration).
To enter the BIOS setup menus:
•Press F2 after the POST RAM test has completed.
•Make the necessary changes by following directions on the screen.
•Press ESC.
•Press ENTER twice to save the settings and exit.
Refer to the CPU manual for more information on the Setup Menu.
Preparing for the Tests
To test your system, you need the following equipment:
•Floppy disk drive
•IBM PC/AT or PS/2-compatible
•Xycom System Test Disk 3.5 inch, DS/DD disk (bootable), Xycom part number
99290-001
•Centronics-compatible printer cable
•Parallel printer (Centronics-style interface)
•Two serial loopback test connectors (refer to Figure 2- 1 for pinouts)
•Formatted 3.5-inch, DS/HD (1.44 Mbyte) disk

3500 Flat Panel Industrial PCs
14
Perform the following steps before starting the system tests:
1. Place the CPU board jumpers and switches to the factory set positions. Refer to
the 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, Serial Loopback
Connections, illustrates the wiring necessary for the loopback connection.
4. Default the CMOS setup to the factory settings.
Figure 2- 1. Serial Loopback Connections

Chapter Two - Testing
15
Running the Tests
To run the test, insert the diagnostics disk into drive A. Turn on the computer (the
diagnostics program will boot-up). Figure 2- 2 shows the Main Menu.
Copyright 1990-1998, Xycom, Inc. All rights reserved.
Diagnostic Tests Sequence/Selection Menu (Rel. xx)
1. WILL pause on error
2. SINGLE PASS test mode
3. Save setup to file
4. Extract setup from a file
5. Auto-select tests
6. Deselect all tests
7. Quit and exit to DOS
8. Return to previous screen
A) RAM Test
B) Video RAM Test
C) Extended RAM Test
D) Real Time Clock Test
E) COM1 Serial Port Test
F) COM2 Serial Port Test
G) COM3 Serial Port Test
H) COM4 Serial Port Test
I) Math Coprocessor Test
J) Video Adjustments Test
K) Video Interface Test
L) Speaker Port Test
M) LPT1: Printer Port Test
N) LPT2: Printer Port Test
O) C: Hard Drive Interface Test
P) D: Hard Drive Interface Test
Q) A: Floppy Drive Interface Test
R) B: Floppy Drive Interface Test
S) Keyboard, Keypad Tests
≡= 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
Note
Please read the DIAG.TXT file on the diagnostics disk for detailed information about
the tests.
Note
Avoid repeated running of any hard disk diagnostic utility if you use the Solid State
(Flash) drive option. The Flash drive has a limited number of writes to each logical
sector. Repeated writes from a diagnostic utility will prematurely shorten the life of the
drive.

Chapter Three - Installation
17
Chapter 3 – Installation
This chapter illustrates the installation of, and the options for, the 3500. The figures
on the next several pages show the internal and external components on the front and
back panels of the unit to help you locate features relevant to installation.
Front Panel
The 3500 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.
3510T/12T Front Panel
Figure 3-1. 3510T/3512T Front Panel

3500 Flat Panel Industrial PCs
18
Feature Description
Display The 3510 has a 10.4-inch TFT Active Matrix Color LCD flat panel. Impact-
resistant shield protects the display from breakage. The 3512 has a 12.1”
TFT Active Matrix Color LCD flat panel. An impact-resistant shield
protects the display from breakage. If a touchscreen is factory installed, it
is backed by heat-annealed safety glass replacing the impact-resistant
shield.
Diagnostic LEDs Following is a description of the LEDs and what it means when they're lit:
Power Lit when the system has power
Disk Lit when the computer is accessing the disk drive
COM Lit when there is communication activity on one of the serial
ports, including communication between the computer module
and the touchscreen (if on COM2) or a serial mouse.
Input Lit when the unit has a touchscreen (LED gets brighter when a
touch input is detected) or a key is pressed
During power-up, firmware on the processor board checks the hardware
configuration against the configuration stored in the CMOS memory.
IR (Infrared) The IR port transceiver is located behind this window. The IR port is IrDA
and ASKIR compliant. Connect the unit to any IrDA compatible device.
Load special software (not included) to use this feature. The infrared (IR)
link is designed to operate at a distance of 0 to 1 meter. Enable the
interface through the BIOS setup menu. Note: When the IR port is
chosen in the system BIOS, COM2 is not available.
Keyboard Port Access
(Optional front access) The 3510/3512 supports one PS/2 keyboard. Front access options are available with the use of the 9000-FKA Front floppy/keyboard access kit
(not shown). The access is a PS/2 stacked mini-din located on the side of
the unit. Warning: To maintain safe conditions, do not use an external
keyboard and/or mouse port when the unit is operating in a hazardous
environment.
Floppy Disk Drive (Optional) The 3510/3512 has front access options available. (Refer to the External
Floppy Option section within this chapter.)

Chapter Three - Installation
19
3510KP/3512KP and 3510KPT/3512KPT Front Panel
The 3510KP and 3512KP have NEMA/4/4X/12 sealed front panels. The panel
protects the system’s interior when the system is properly panel mounted. Figure 3-2
illustrates the front panel with keypad.
Figure 3-2. 3510KP/12KP Front Panel
Feature Description
Display The 3510KP/3512KP has a 10.4-inch (640 x 420) TFT flat panel
display or a 12.1-inch SVGA (800 x 600) TFT flat panel display.
Diagnostic LEDs The 3510KP/3512KP features status LEDs on the front panel,
which allows monitoring of the system operation. Following is a
description of the LEDs and what it means when they're lit:
Power Lit when the system has power
Disk Lit when the computer is accessing the disk drive
COM Lit when there is communication activity on one of
the serial ports, including communication between
the computer module and the touchscreen (if on
COM2) or a serial mouse.
Input Lit when the unit has a touchscreen; the LED gets
brighter when a touch input is detected or a key is
pressed.
F/A key Indicates the keypads are in alpha mode
Function and User-Defined Keys These 32 relegendable function keys (64 using the F/A keys)
provide easy access to familiar routines. (F/A keys can be used
for alpha and symbol entry). See the Customizing Keypad
Inserts section in this chapter for details on customizing your
keypad inserts.
Numeric/Cursor Control Keypad Use the data entry keypad to enter data and move the cursor.

3500 Flat Panel Industrial PCs
20
Feature Description
PF10 Key (Keypad Configuration Key) This key reconfigures your keypad.
Keyboard Port (3510KP/3512KP)
(front access) The 3510KP/3512KP provides both front and rear accessible PS/2 keyboard connectors. The front accessible connector is
located on the lower right side of the front panel. The rear
accessible connector is located on the side of the unit.
Note: Only one keyboard port on the 3510/3512KP can be used
at a time.
Note: The installation of the touchscreen driver determines
whether a second pointing device will function correctly. If using
a mouse with a touchscreen, please review the Touchscreen
Driver Installation instructions.