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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 does not guarantee the accuracy of the information.
Chapter 2 – Testing ........................2-1 Preparing for the Tests ................................2-1 Running the Tests ..................................2-3 Chapter 3 – Installation ........................3-1 Front Panel....................................3-1 9460/9462 Front Panel................................3-1 9460KP/9462KP Front Panel..............................3-3 I/O Panel....................................3-5 Back Panel....................................3-6 Power Panel.................................... 3-7 Preparing the System................................
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9460/9460KP/9462/9462KP System Manual Installing the System into a Panel............................3-22 Mounting Considerations..............................3-23 System Power..................................3-23 Excessive Heat..................................3-24 Electrical Noise..................................3-24 Line Voltage Variation ................................ 3-25 Creating a Power Cable ................................3-25 AC Power Cable................................... 3-25 DC Power Cable ................................... 3-26 Mounting the Unit ................................
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Chemical Compatibility ................................5-3 Compatible Lubricants................................5-4 Compatible Cleaning Agents............................... 5-5 Non-compatible Cleaning Agents ............................5-5 Spare Parts List..................................5-6 Product Repair Program/Returning a Unit to Xycom......................5-7 Appendix A – Technical Specifications..................A-1 Hardware Specifications..............................A-1 Environmental Specifications.............................A-2 Appendix B – Block Diagram ......................B-1 Appendix C –...
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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 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.
PC and a durable industrial enclosure. The system integrates a computer card cage, mass storage, display, and power supply in a truly industrial form factor. The front panels of the units are sealed to NEMA 4/4X/12 and IP65 (9460/9462 only), standards and is protected by an impact-resistant shield. The 9460KP and 9462KP ver- sions are sealed to NEMA 4/4X/12.
™ cluded) • Sealed front panels • 9460/9462 to NEMA 4/4X/12 and IP65 specifications when panel mounted • 9460KP/9462KP to NEMA 4/4X/12 specifications when panel mounted • UL listed for use in Class I, Division 2 hazardous locations Optional Features Following are optional features available for the units: •...
• 4100 WIN, Microsoft Windows version 3.11 • 8000-KBX, various sealed rack or panel mount keyboards • 9000-RF1 19-inch Rack Mount Adapter Plate (9460, 9462) • 9000-FFK Front Floppy Kit • 9000-RFC 19-inch Floppy Door Plate • 2000-RMA 190inch Rack Mount Adapter Plate (9460KP, 9462KP) Unpacking the System When you remove the system from its box, verify that you have the parts listed below.
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9460/9460KP/9462/9462KP System Manual 4. Turn on the power to the unit. The system will boot up into the operating system. 5. Adjust the contrast on the unit by using the contrast adjust keys on the front panel. These keys are available on the STN passive color option only.
Chapter 2 – Testing On units with MS-DOS, Xycom provides diagnostic tests to verify the operation of the system hardware functions. If any of these tests fails, either you do not have the correct default setting or there is a failure. Check the default settings and run the tests again. If another failure occurs, contact Xycom’s Product Repair &...
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9460/9460KP/9462/9462KP System Manual Perform the following steps before starting the system tests: 1. Place the CPU board jumpers and switches to the factory set positions. Refer to your CPU manual for these settings. 2. Plug the female end of the AC power cable into the side of the unit and the male end into a properly grounded outlet.
To run the test, insert the diagnostics disk into drive A. Turn on the computer (the dia g- nostics program will boot-up). Figure 2- 2 shows the Main Menu. Copyright 1990-1996, Xycom, Inc. All rights reserved. Diagnostic Tests Sequence/Selection Menu (Rel. xx) 1.
Chapter 3 – Installation This chapter illustrates the installation of and the options for the 9460/9462. 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.
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IR (Infrared) The IR port transceiver is located behind this window. The 9460/9462 IR port is IrDA and ASKIR compliant. You can connect the 9460/9462 to any IrDA compatible device. You must 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.
Chapter 3 – Installation 9460KP/9462KP Front Panel The 9460KP/9462KP comes with a NEMA/4/4X/12 sealed front panel. The panel pro- tects the system’s interior when the system is properly panel mounted. Figure Chapter 3 - 2 illustrates the front panel with keypad. Figure Chapter 3 -2.
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9460/9460KP/9462/9462KP System Manual Feature Description Display The 9460KP/9462KP comes with a 10.4-inch (640 x 420) STN or TFT flat-panel display or a 12.1-inch SVGA (800 x 600) STN or TFT flat-panel display. Diagnostic LEDs The 9460KP/9462KP features status LEDs on the front panel, which allow you to monitor system operation.
Chapter 3 – Installation I/O Panel Figure Chapter 3 -3 illustrates the I/O Panel. Figure Chapter 3 -3. System I/O Panel Feature Description Parallel Port The parallel printer port (LPT1) is a DB-25 pin female connector. This port provides a standard PC compatible printer interface.
“Simultaneous Video” on the Advanced Menu in the BIOS setup. Refer to the CPU manual for details. Note: The 9460/9462 does not support simultaneous flat panel and CRT with an STN passive flat-panel display.
Chapter 3 – Installation Feature Description External Floppy Disk Drive (Optional) You can install an external floppy disk drive to the back of the system. Front access options are also available. Power Panel Figure Chapter 3 -5 illustrates the bottom panel. Figure Chapter 3 -5.
9460/9460KP/9462/9462KP System Manual Preparing the System Read this chapter first, comply with all the safety requirements, then mount the unit ac- cording to the following instructions. 1. Locate a position that meets the required specifications 2. Do a panel cutout. The dimensions are given in this chapter.
Chapter 3 – Installation PC/AT and PCI Boards 1. Check that the memory and I/O configuration of the board you want to install does not conflict with the CPU and I/O memory maps in your CPU board manual. 2. Remove the lid. 3.
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9460/9460KP/9462/9462KP System Manual If you wish to relocate the floppy drive to the front of the computer module, you must in- stall the 9000-FFK Front Floppy Kit, which includes a front access keyboard port. The floppy drive access door is provided for installations using the 9000-RFC Rack Filler Plate with Cutout, or panel mount installations that provide a cutout for the front mounted floppy drive.
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Chapter 3 – Installation Figure Chapter 3 -7. Floppy Drive - Front Mounting Option Figure Chapter 3 -8 shows an overhead view of the Front Floppy Kit with the floppy drive mounted. Figure Chapter 3 -8. Floppy Drive - Front Mounting Option (top view) 3-11...
9460/9460KP/9462/9462KP System Manual Front Connector Access If you wish to access the keyboard and external floppy connectors from the front of the computer module, you must install the 9000-FKA kit. Figure Chapter 3 -9 provides cutout dimensions for the 9000-FKA (optional front con- nector option).
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Chapter 3 – Installation Figure Chapter 3 -10 illustrates the front floppy and keyboard access kit. Mount the kit to the plate or the panel as shown. Figure Chapter 3 -10. Front Floppy and Keyboard Access Option Warning To maintain a safe condition, do not use an external keyboard and/or mouse port when the unit is operating in a hazardous environment.
These keyboards are not available in the E.U. (no CE mark). Serial Mouse To install Xycom’s 4100-MS1 two-button serial mouse, attach the connector on the mouse cable to COM1 or COM2 on the side panel. If a mouse is used, the ferrite in the documentation kit must be installed to maintain CE compliance.
You have the option to place a custom label on the unit. Refer to the following figure for the dimensions and recommended requirements for a customized label. Once a custom- ized label is procured, place the new label over the “Xycom” label (inside the recessed area).
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9460/9460KP/9462/9462KP System Manual Figure Chapter 3 -13. 9460KP/9462KP Insert with Dimensions (F1 - F20) Figure Chapter 3 -14. 9460KP/9462KP Keypad Insert Position 3-16...
Chapter 3 – Installation Installing Operating Systems The system CPU comes with MS-DOS standard The pre-installed operating systems are provided in the following format: Operating Systems Format DOS and Windows 3.11 Disk Windows 95 CD ROM or disk Windows NT CD ROM If you want to install a new operating system or re-install a current operating system, re- fer to the operating system’s manual for directions.
9460/9460KP/9462/9462KP System Manual If you install Windows 3.1 on your system, Xycom provides the Ethernet drivers on the Ethernet Drivers disk that ships with your system. Note If you install Windows NT 4.0 or Windows 95 on your system, the Ethernet drivers that are provided do not work with the Ethernet con- troller installed.
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Chapter 3 – Installation filled by the 640 x 400 resolution of this particular mode. By enabling the expansion function, these lower resolutions will better utilize the display by stretching the informa- tion in an attempt to fill the display. Operating systems such as Microsoft Windows 3.X, Windows 95, and Windows NT use display drivers to handle the different flat panel dis- plays.
Note A STN flat-panel display and a CRT cannot be used simultaneously. Note For further assistance, call Xycom technical support at 1-800-289-9266. Touch Screen Drivers If you have a touch screen factory-installed, you will also receive at no charge: MS-DOS, Windows 3.x, and Windows 95 touch screen drivers on diskette.
NT drivers. The Windows NT operating system only ships on CD-ROM. Using a Touch Screen Xycom’s touch screen complies with environmental specifications and maintains a NEMA 4 seal when panel mounted. It remains operational even after 30 million touches. The touch screen Monitor Mouse driver emulates a Microsoft mouse.
9460/9460KP/9462/9462KP System Manual 4. Reconfigure Jumpers J1-J5. Position A = COM2. Position B = PS/2 mouse. 5. Reinstall the touch screen controller card. 6. Reboot the computer. 7. Using the touch screen manual do the following: Load the touch screen drivers.
Chapter 3 – Installation Mounting Considerations Once you have established a location for the 9460/9462, install it in the enclosure ac- cording to the instructions that follow: • Select a NEMA rated enclosure and place the unit to allow easy access to the system ports.
9460/9460KP/9462/9462KP System Manual continuous, and able to safely conduct the ground-fault current in the system with mini- mal impedance (minimum wire required is 18 Awg, 1 mm). Observe the following practices: • Separate ground wires (P.E. or Protective Earth) from power wires at the point of entry to the enclosure.
If this correction does not solve the problem, use a constant volt- age transformer. The constant voltage transformer stabilizes the input voltage to the 9460/9462 by com- pensating for voltage changes at the primary in order to maintain a steady voltage at the secondary.
9460/9460KP/9462/9462KP System Manual 4. Insert the three wire ends of the power cable into the three holes of the block plug. Insert the Protective Earth GND ground, L1, and L2/N wires into the corresponding holes, as shown in Figure Chapter 3 -16. Be sure that no bare wires are exposed.
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Chapter 3 – Installation 3. Tin the wire ends with solder if using stranded wire. This will keep the wire from fraying. Warning When inserting the wire ends of the power cable into the block plug, be sure there is no exposed wire. Trim the wire ends of the cable or cut a new cable if necessary.
A 6-32 threaded ground point hole is provided on the bottom panel of the unit. 7. Tighten the 12-#10 nuts to 25 inch-lbs (2.8 Newton-meters) (28Kgf cm). System Cutout Dimensions 9460/9462 Figure Chapter 3 -18. 9460/9462 System Cutout Dimensions 3-28...
Pentium MMX Processor) Hazardous Location Installations Xycom designed the systems to meet the requirements of Class I, Division 2 Hazardous Locations applications. Division 2 locations are those locations that are normally non- hazardous, but could become hazardous due to accidents that may expose the area to flammable vapors, gases or combustible dusts.
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DC power line. Any such installations are beyond the bounds of Xycom design intent. Xycom accepts no re- sponsibility for installations of this equipment or any devices attached to this equipment in Division 1 locations.
Chapter 3 – Installation Warning - Explosion Hazard When in hazardous locations, turn off power before replacing or wiring modules. Advertissement Risque D’ Explosion Dans les situations hasardees, couper la courant avant de remplacer ou de cabler les modules. Warning To maintain a safe condition, do not use an external keyboard or mouse when the unit is operating in a hazardous environment.
9460/9460KP/9462/9462KP System Manual Note Xycom systems are not suitable for installation within Division 1 loca- tions. Note Electrical equipment cannot be installed in Division 1 locations unless they are intrinsically safe, installed inside approved explosion-proof en- closures, or installed inside approved purged and pressurized enclosures.
United States. Power Switch The 9460/9462 systems do not have a power switch. The amount of input power required by these systems classifies the power switch as an incendiary device because the voltage and current across the make/break device are capable of creating a spark.
9460/9460KP/9462/9462KP System Manual All communication cables should include a chassis ground shield. This shield should in- clude both copper braid and aluminum foil. The D-sub style connector housing should be a metal conductive type (e.g., molded zinc) and the ground shield braid should be well terminated directly to the connector housing.
Chapter 3 – Installation Safety Agency Approval These systems have the following approvals: • Underwriters Laboratories Inc., UL 1604 Standard for Safety Electrical equipment for use in Class I and Class II, Division 2, and Class III hazard- ous (classified) locations (UL listed, File E180970) •...
The PKIM utility uses a menu bar and pull-down menu system. All menu bars are dis- played across the top of the screen. “Xycom PKIM Utility” and the current menu titles are shown at the bottom of the screen (see Figure Chapter 4 -1).
Files Macros Upload Download Utilities Xycom PKIM Utility: MAIN L-Arrow, R-Arrow, Enter Figure Chapter 4 -1. Main Menu Exit Exit closes open files and exits the utility. can also be used for this purpose and for exiting the other menus.
Chapter 4 – Programmable Keypad Utility Program (9460KP/9462KP) Files Menu Files containing keypad macro sets (a macro for each key) may be saved on disk and loaded into memory to view, edit, teach, or download to the keyboard controller. Some of these files may be included in the utility package for use in reconfiguring the keypads for different software packages and as templates for defining completely new keypad macro sets.
9460/9460KP/9462/9462KP System Manual Function Keys Selects the function keys on the keypad to either view, edit, or teach. Alpha Keys Selects the alpha keys on the keypad to either view, edit, or teach. Exit Returns to the main menu. Macros Edit Menu Exit Returns to the Main Menu.
Chapter 4 – Programmable Keypad Utility Program (9460KP/9462KP) To select a key to define, use the arrow keys to position the cursor on the desired key and press . After a key is selected, the utility records every key stroke on the external ENTER full-stroke keyboard in a macro assigned to the chosen key.
9460/9460KP/9462/9462KP System Manual Paste Insert a sequence of scan codes (which were saved in memory using Copy) into the macro. To paste a sequence of scan codes that were previously copied, position the cur- sor where you want the text to appear and then press 1.
Chapter 4 – Programmable Keypad Utility Program (9460KP/9462KP) Download Menu Note Any macro set previously programmed is overwritten when you select Download. Download sends the set of keypad macros to the keyboard controller. The macro set must reside in memory before it can be downloaded. A checksum is calculated during transmis- sion and an error message displays if an error occurs.
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9460/9460KP/9462/9462KP System Manual Special PKIM Scan Codes Code Meaning Insert Home Page Up Delete Page Down Up Arrow Left Arrow Right Arrow Down Arrow Forward Slash Print Screens/Sys Rq Pause/Break The following table lists the default keypad keycodes the PKIM utility produces.
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Chapter 4 – Programmable Keypad Utility Program (9460KP/9462KP) 9462KP F/A key LED off (Function mode) F/A key LED on (Alpha Mode) Description of Keyboard Make Break Keyboard Make Codes Break Equivalent Codes Codes Equivalent Codes CTRL CTRL F0 14 CTRL F0 14 SHIFT SHIFT...
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9460/9460KP/9462/9462KP System Manual 4-10...
Chapter 5 – Maintenance The 9460/9462/9460KP/9462KP was designed to withstand the harsh environment of the factory floor. Routine maintenance can help keep your system in good operating condition. Preventive maintenance consists of several basic procedures that will greatly reduce the chance of system malfunction.
This section describes the maintenance you can perform on the 9460/9462. Fuse Replacement The 9460/9462 has no accessible fuse. Return the unit to Xycom for fuse replacement. Fan Filter Replacement To change the fan filter, remove the grill and filter as illustrated in Figure Chapter 5 -1.
Certain combinations of chemical environments, temperature, and stress can adversely af- fect parts made from thermoplastic resin. For this reason material which may come in contact with the 9460/9462 unit should be carefully evaluated under end-use conditions for compatibility. You should also follow the use and compatibility recommendations of the material manufacturer.
9460/9460KP/9462/9462KP System Manual Compatible Lubricants The following table lists known compatible lubricants and the manufacturer’s names. If you want to use a lubricant that is not listed below, contact the appropriate manufacturer for compatibility. Lubricants Manufacturer DC® 230 Dow Corning Midland, MI 48640 Molykote®...
(less than 10 minutes). If parts are in complete immersion, care should be taken to remove last traces of solvent by forced-air drying or rinsing in hot water. Non-compatible Cleaning Agents The following cleaning agents are known to be detrimental to the 9460/9462 unit. Type Agents Bases...
9460/9460KP/9462/9462KP System Manual Spare Parts List Xycom Part Number Xycom Part Number Description 9460 9462 Front Panel Assembly Touch screen 117321-101 119032-101 117334-101 119045-101 132274-001 132290-001 (panel assembly includes T/S control- ler) Non-touch 117321-001 119032-001 117334-001 119045-001 132261-001 132287-001 Drives Hard Drive–2160 Mbytes...
Xycom tests products returned to Xycom with the standard Xycom test di- agnostics. Follow the steps below to prepare the unit for shipment: 1. Obtain an RMA number for your unit by calling your nearest Xycom Repair Depart- ment or Xycom, Inc. at 1-800-289-9266 or 313-429-4971. Please have the following information: •...
9460/9460KP/9462/9462KP System Manual Environmental Specifications nvironmental Specifications Characteristic Specification Temperature Operating 0° to 50° C (32° to 122° F) TFT Non-operating -20° to 60°C (-4° to 140°F) Humidity Operating 20% to 80% RH non-condensing Non-operating 20% to 80% RH non-condensing...
Appendix C – Pinouts This appendix provides the AHIP4+ and the AHIP5+ pinouts for the keyboard, mouse, LPT1, COM1, COM2, and VGA connectors. The following table defines abbreviations used in this Appendix. Abbreviation Definition No connect Keyboard Port Connector This double stacked connector provides an upper and lower connector for the keyboard and mouse port.
Appendix C – Pinouts Serial Port Connectors There are two serial ports supported on the AHIP4+ and the AHIP5+ boards. COM1 COM1 consists of two connectors attached to one logical port. Only one connector can be used at a time either the RS-232 port or the RS-485 port. All termination is done out- side the unit.
9460/9460KP/9462/9462KP System Manual COM2 COM2 is connected to a 25 pin DB that sits on top of the parallel port. RS-232 Signal ORB_GND TXD2 RXD2 RTS2 CTS2 DSR2 DCD2 PB_RESET DTR2...
Appendix C – Pinouts VGA Connector The VGA connector is a 15-pin connector. AHIP4+ Signal GREEN BLUE ORB_GND ORB_GND ORB_GND ORB_GND ORB_GND HSYNC VSYNC AHIP5+ Signal GREEN BLUE ORB_GND ORB_GND ORB_GND ORB_GND Fused VCC ORB_GND DDCDAT HSYNC VSYNC DDCCLK...
9460/9460KP/9462/9462KP System Manual Floppy Connector The floppy interface supports only Xycom’s external floppy option. Signal Signal FSTEP FDS1 DCHG FTK0 FRDD FDIRC...
This appendix describes how to replace the bulbs in your flat-panel display. We recom- mend you send the flat-panel display to Xycom for bulb replacement. However, if you would like to replace the bulbs on site, refer to the following instructions.
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16. Replace the cover, and insert and tighten the bulb assembly cover screws. Note Xycom recommends replacing both bulbs at the same time. 17. Repeat steps 11 through 16 to replace the second bulb assembly. 18. Reverse steps 1 through 10 to reassemble the unit.
Appendix D – Replacing Flat-Panel Display Bulbs Sharp TFT Flat-Panel Display (model #LQ10D421) 1. Turn off the power source. 2. Using a small Phillips-head screwdriver, loosen the two protruding captive screws at the top back of the unit, and remove the lid. 3.
12. Slide the new assembly into the opening from which the old assembly was removed. Note Xycom recommends replacing both bulbs at the same time. 13. Repeat steps 10 through 12 to replace the bulb assembly on the right, outside edge of the flat-panel display.
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Appendix D – Replacing Flat-Panel Display Bulbs 9. Gently lift the right side of the flat-panel display, and disconnect the data interface connector. 10. Lay the flat-panel display faceup on a flat surface. 11. Referring to Figure Appendix D -3, remove the five smaller bezel mounting screws. Figure Appendix D -3.
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9460/9460KP/9462/9462KP System Manual Figure Appendix D -4. Model #AA12SB6C-ADFD Bulb Assembly - Rear View 15. Because the white wire runs under the bulb assembly, detach the rear of the display from the front with a small flat-bladed screwdriver. 16. Lift the rear display panel section to expose the full bulb assembly. Note how the wiring on the bulb assembly is routed.
Appendix D – Replacing Flat-Panel Display Bulbs Kyocera STN Flat-Panel Display (Model #KCB8060BSTT-X4) 1. Turn off the power source. 2. Using a small Phillips-head screwdriver, loosen the two protruding captive screws at the top back of the unit, and remove the lid. 3.
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13. Insert the new bulb assembly by placing it over the notches and sliding it until the release tab locks. Note Xycom recommends replacing both bulbs at the same time. 14. Repeat steps 11 through 13 to replace the second bulb assembly. 15. Reverse steps 1 through 9 to reassemble the unit.
Appendix D – Replacing Flat-Panel Display Bulbs Sharp 12.1" TFT Flat-Panel Display (Model #LQ12S41) 1. Turn off the power source. 2. Using a small Phillips-head screwdriver, loosen the two protruding captive screws at the top back of the unit, and remove the lid. 3.
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13. Insert the new bulb assembly, and push in until the tab locks in place. Note Xycom recommends replacing both bulbs at the same time. 14. Repeat steps 12 and 13 for the second bulb assembly. 15. Reverse steps 1 through 10 to reassemble the unit.