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