Chapter 1: Manual Overview and Support Services Using this Manual Using this This manual is designed to help you set up and use your P1 PowerStation. The manual lists the PowerStation’s Manual specifications and describes its replacement and optional components. It also explains how to install the unit, how to maintain the unit in good condition, and how to solve common problems that may occur in operation.
Chapter 1: Manual Overview and Support Services Documentation Components Documentation The P1 PowerStation documentation set contains all the information you need to configure, install, and use the P1 Components PowerStation. The P1 PowerStation documentation set is described below. Release Notes - This document is provided whenever there is important information about the P1 PowerStation that does not appear in this manual.
Chapter 1: Manual Overview and Support Services Getting Started Getting Started Now that you have opened the PowerStation package, you are ready to unpack the unit, develop an application, and install the P1 in a permanent location. This section provides an overview of these activities. Additional infor- mation is available in the remaining chapters of this manual.
Chapter 1: Manual Overview and Support Services Documentation Standards Documentation As you read this manual, you will notice that it uses the following documentation standards: Standards 1. Important terms are shown in bold. 2. Text to be entered from the keyboard is shown in Courier font.
Chapter 1: Manual Overview and Support Services Customer Support Services Customer CTC Parker welcomes your thoughts and suggestions on our products and services. You can contact CTC Parker by Support telephone, email, or fax. You can also visit CTC Parker on Services the World Wide Web to learn the latest about our hard- ware, software, and customer support services.
Chapter 1: Manual Overview and Support Services Customer Support Services Technical Support Our Technical Support Products department provides service in two areas: training and consulting. CTC Parker Products offers training on all our products, either at CTC Parker in our state-of-the-art training center or at your site. You can learn how to write custom interfaces, develop specialized applications, and implement your complete operator inter- face application.
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Chapter 1: Manual Overview and Support Services Customer Support Services P1 PowerStation User Guide...
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C h a p t e r 2 I n t r o d u c i n g t h e P 1 P o w e r S t a t i o n The P1 PowerStation is designed to give you an operator interface solution that is powerful, cost-effective, and very easy to use.
Chapter 2: Introducing the P1 PowerStation Specifications Specifications This section describes important specifications for the P1 PowerStation. Please familiarize yourself with these spec- ifications before operating the unit. Physical Physical specifications include the PowerStation’s CPUs, memory specifications, display types, storage capacity, Specifications and other physical characteristics.
Chapter 2: Introducing the P1 PowerStation Specifications Important For the Color STN display, you must set the Display Color to Color on the Run Mode Display tab in the Interact Settings dialog box. For the Monochrome display, you must set the Display Color to Gray on the Run Mode Display tab in the Interact Settings dialog box.
Chapter 2: Introducing the P1 PowerStation Specifications Electrical The PowerStation’s electrical specifications appear in the Specifications table below. Category Specifications Output rating Input voltage 18-30VDC Output voltage +5V@4A, +12V@0.5A Important The PowerStation’s power supply automatically detects the input voltage level and adjusts accord- ingly.
Chapter 2: Introducing the P1 PowerStation Specifications Faceplate Chemical The touchscreen of the PowerStation can resist the chem- icals listed in the table below with no visible effect. Resistance Touchscreen Chemical Resistance Acetone Sulfuric Acid 10% Motor oil Hydrochloric Acid Gasoline Toluene Acetic Acid 10%...
Chapter 2: Introducing the P1 PowerStation Available Connectors • Alcohol (ethyl, methyl) • Automatic transmission fluid ® Important Sustained exposure to brake fluid or Gunk brand degreaser can cause damage to monitor materials. Available The P1 PowerStation includes many of the same ports found on most PCs.
Chapter 2: Introducing the P1 PowerStation Available Connectors RS-422 and RS-485 communications offer greater noise immunity than RS-232-C. These standards increase the maximum cable length to 4,000 feet (1,200 meters). RS-422 communications are full-duplex (can send and receive simultaneously), while RS-485 communications are half-duplex (can only send or receive at one time).
Chapter 2: Introducing the P1 PowerStation Available Connectors COM2 pinouts If you need to make a cable for communicating with COM2, the following table shows the pinouts and signal information for this port. COM2 is set to the RS-485 protocol by default. To change COM2 to the RS-232-C or RS-422 protocol, you must change the COM2 DIP switch settings.
Chapter 2: Introducing the P1 PowerStation Available Connectors COM2 DIP switch settings If you need to make a cable for communicating with COM2, you also need to set the DIP switch settings for this port. The DIP switch for COM 2 is located on the top of the PowerStation Unit, as shown below.
Chapter 2: Introducing the P1 PowerStation Available Connectors COM2 DIP Switch Settings RS-485 Cable diagrams The following illustrations represent the pinouts and cable diagrams required for communicating with COM1 or COM2 using the RS-232-C protocol. Also shown are cable diagrams for communicating with COM2 using the RS-422 or RS-485 protocol.
Chapter 2: Introducing the P1 PowerStation Available Connectors Connecting to a PC To transfer files from a PC to the PowerStation, connect a serial cable with a null modem to an available serial port on the PC. Connect the other end of the cable to the serial port on the PowerStation.
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Chapter 2: Introducing the P1 PowerStation Available Connectors If you still find it necessary to use a serial mouse, follow these steps to configure the PowerStation to accept a serial mouse: 1. On the MachineShop Shell menu, press Exit to enter MS-DOS mode.
Chapter 2: Introducing the P1 PowerStation Available Connectors Connecting to a serial printer To connect a serial printer to the PowerStation, you must change the mode settings for one of the serial ports to match those of your printer. The easiest way to change these settings is to use MODE.COM.
Chapter 2: Introducing the P1 PowerStation Available Connectors When MachineShop finishes the download, you will be asked if you want to restart the PowerStation. When you restart, MODE.COM will configure the COM port to the required baud rate. For example, if you are communi- cating at 9600, NONE, 8, and 1, use: MODE COM1: 9600,N,8,1 Note...
Chapter 2: Introducing the P1 PowerStation Available Connectors Pin # Signal Name DATA 5 DATA 6 DATA 7 - ACKNOWLEDGE BUSY PAPER EMPTY + SELECT - AUTO FEED - ERROR - INIT PRINTER - SELECT INPUT 18-25 GROUND Connecting to a parallel printer The PowerStation can interface with any parallel printer designed for use with IBM PC-compatible computers.
Chapter 2: Introducing the P1 PowerStation Available Connectors CTC has found that some Microsoft-compatible PS/2 mice do not work correctly with the PowerStation. In addition, connecting any mouse directly to the keyboard port will cause the mouse to malfunction. Ethernet Port The PowerStation has an Ethernet RJ-45 port that allows you to connect the PowerStation to a Local Area Network.
Chapter 2: Introducing the P1 PowerStation Drive Definitions and Memory Map Drive The table below provides information about the P1 PowerStation’s drive definitions. Following the table is an Definitions and illustration of the PowerStation’s memory map. Memory Map Drive Type Size Letter Compact Flash...
Chapter 2: Introducing the P1 PowerStation Drive Definitions and Memory Map P1 PowerStation The figure below illustrates how the P1 PowerStation allocates conventional memory and extended memory. Memory Map The range of address references is listed next to each device. P1 PowerStation User Guide...
Chapter 2: Introducing the P1 PowerStation PC/104 Adapter Memory Guidelines If you are using MachineShop to develop your HMI appli- cations, refer to the memory guidelines listed below when you develop projects. The following table lists guidelines concerning the capacity and use of memory for runtime and development systems.
Chapter 2: Introducing the P1 PowerStation Replacement Components Replacement The P1 PowerStation is designed to be a simple yet reli- able unit to maintain. However, if you need to purchase Components replacement components for the PowerStation, CTC Parker carries a complete line of replacement compo- nents.
Chapter 2: Introducing the P1 PowerStation Optional Components Optional CTC Parker carries two optional components that you may wish to purchase for the PowerStation: an AC Power Components Supply and PC/104 cards. AC Power Supply The P1 PowerStation uses DC power to save space and limit the amount of heat generated by the unit.
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Chapter 2: Introducing the P1 PowerStation Optional Components P1 PowerStation User Guide...
Chapter 3: Installing the PowerStation Selecting a Location Selecting a The first step in installing the PowerStation is to select an appropriate location for the unit. This is the most impor- Location tant aspect of the installation process because the location you select can affect the PowerStation’s performance, ease-of-use, and life-expectancy.
Chapter 3: Installing the PowerStation Selecting a Location The PowerStation’s touchscreen is resistant to a variety of chemicals. See Faceplate Chemical Resistance on page 13 of this manual for a list of these chemicals. Make sure that the touchscreen is exposed only to the chemicals on this list.
Chapter 3: Installing the PowerStation Selecting a Location Also, make sure that the surface of the enclosure on which the PowerStation is mounted is flat and free of raised or depressed areas. Backlight and Occasionally, you may need to replace the PowerStation’s backlight bulb or touchscreen.
Chapter 3: Installing the PowerStation Preparing for Installation Preparing for Once you have selected a location for the PowerStation, you can begin preparing it to accept the unit. Before Installation installing the PowerStation, you will need to create a cutout for the unit and clean the area of any dirt or debris that might come in contact with the unit.
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Chapter 3: Installing the PowerStation Preparing for Installation If you plan to operate the PowerStation with AC power, and you have purchased CTC’s optional AC Power Supply and the AC Power Supply Mounting Kit, you will receive with the Mounting Kit a template that you can use to prepare a location for the Power Supply.
Chapter 3: Installing the PowerStation Installing the PowerStation Installing the Once you have prepared the location for the PowerSta- tion, you can install the unit. Installation will involve PowerStation mounting the PowerStation and, if you are using CTC’s optional AC Power Supply, mounting the Power Supply. Both procedures are described below.
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Chapter 3: Installing the PowerStation Installing the PowerStation The AC Power Supply is designed to be mounted using two metal brackets found in the AC Power Supply Mounting Kit. These brackets are secured to the mounting surface using four screws. To mount the Power Supply, complete the following steps: 1.
Chapter 3: Installing the PowerStation Starting Up the PowerStation Starting Up the Once the PowerStation has been mounted, you are ready to start up the unit. This procedure is described below. PowerStation Before connecting a power cord to your unit, make sure that you have read and understood Electrical Specifica- tions and Testing Specifications on page 12 of this manual.
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Chapter 3: Installing the PowerStation Starting Up the PowerStation P1 PowerStation User Guide...
C h a p t e r 4 M a i nt a i n in g an d T r o u b l e s h o o t i n g t h e P o w e r S t a t i o n The P1 PowerStation has been designed to provide years of trouble-free operation even in the harshest environments.
Chapter 4: Troubleshooting the PowerStation Cleaning the TouchScreen Cleaning the Occasionally, you may wish to clean the PowerStation’s touchscreen. Clean the touchscreen using warm, soapy TouchScreen water and a cloth. You may also use any non-abrasive cleaner. See Faceplate Chemical Resistance on page 13 of this manual for a list of substances the screen can resist with no visible effect.
Chapter 4: Troubleshooting the PowerStation Using the Compact Flash Card Removing and To remove and replace the Compact Flash card, complete the following steps: Replacing the Compact Flash 1. Turn off the PowerStation. Important Make sure that the PowerStation is turned off when inserting or removing the CF card.
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Chapter 4: Troubleshooting the PowerStation Using the Compact Flash Card The procedure requires the following items: • PC with a Type II PCMCIA slot and 3.5" floppy drive, or a CF card reader. The PC should be running MS-DOS 6.22, Windows 95, or Windows 98. •...
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Chapter 4: Troubleshooting the PowerStation Using the Compact Flash Card The computer should recognize and configure the card as an ATA card, assigning it an additional drive letter (e.g., D) Note In this example, drive D represents the PCMCIA card or card reader; however, your system may assign a different drive letter to either of these devices.
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Chapter 4: Troubleshooting the PowerStation Using the Compact Flash Card 13. Press Enter to execute this command. You will be asked whether you wish to install the standard CTC AUTOEXEC.BAT and CONFIG.SYS files as part of the installation. CTC recommends that you type Y for Yes.
Chapter 4: Troubleshooting the PowerStation Reinstalling the PowerStation Utilities 20. Start up the PowerStation. The PowerStation will automatically load the MachineShop Shell. 21. Recalibrate the touchscreen. See Recalibrating the Touchscreen on page 54 of this manual for complete instructions. Reinstalling the The PowerStation utilities come pre-installed on your PowerStation’s Compact Flash card.
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Chapter 4: Troubleshooting the PowerStation Reinstalling the PowerStation Utilities The computer should recognize and configure the card as an ATA card, assigning it an additional drive letter (e.g., D) Note In this example, drive D represents the PCMCIA card or card reader; however, your system may assign a different drive letter to either of these devices.
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Chapter 4: Troubleshooting the PowerStation Reinstalling the PowerStation Utilities 8. After the AUTOEXEC.BAT and CONFIG.SYS files have been copied onto your system, press any key to continue. You will be asked if this installation is for a model P1 PowerStation. Type Y for Yes. The PowerStation Start installation is complete.
Chapter 4: Troubleshooting the PowerStation Reinstalling the Shell Software Reinstalling the The MachineShop Shell comes pre-installed on your PowerStation’s Compact Flash card. If you need to rein- Shell Software stall the Shell, you can do so by using the MachineShop Shell Installation Disk.
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Chapter 4: Troubleshooting the PowerStation Reinstalling the Shell Software 4. Enter MS-DOS mode. 5. Insert the Machineshop Shell Installation Disk. 6. At the DOS prompt, type INSTALL A:\ D:\ You will be asked if you would like to continue with the installation.
Chapter 4: Troubleshooting the PowerStation Modifying the AUTOEXEC.BAT File Modifying the The lines shown in the following table must appear in the PowerStation’s AUTOEXEC.BAT file for the unit to AUTOEXEC.BAT operate properly. The AUTOEXEC.BAT file that CTC File Parker supplies includes these lines and is located in the \CTC directory on the PowerStation’s Flash card in a file called AUTOEXEC.CTC.
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Chapter 4: Troubleshooting the PowerStation Modifying the AUTOEXEC.BAT File Command line parameters Description **SET MACHINELOGIC=C: Sets up MachineLogic \MACHLOG environment variables. CD \NET Loads network drivers --Novell and/or TCPIP LH C: \NET\TCPIP stack. **IF NOT EXIST C: \MACHLOG Loads MachineLogic if \NUL.EXT MD C: \MACHLOG present and set for startup operation.
Chapter 4: Troubleshooting the PowerStation Recalibrating the Touchscreen Recalibrating The PowerStation’s touchscreen is calibrated before leaving CTC Parker. However, you may need to recali- brate the touchscreen when you begin using the Power- Touchscreen Station for the first time or whenever the cursor location and the location on the screen where the user touches do not match.
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Chapter 4: Troubleshooting the PowerStation Recalibrating the Touchscreen 3. Press the Calibrate Touchscreen button. You will be prompted that a keyboard is needed to calibrate the touchscreen. Then you will be asked if you want to continue. 4. If necessary, install a keyboard on the PowerStation. See Keyboard/Mouse Port on page 23 of this manual for information about connecting a keyboard to the PowerStation.
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Chapter 4: Troubleshooting the PowerStation Recalibrating the Touchscreen The PowerStation will beep when you touch the correct point. The graphic below demonstrates where to touch the screen. Touch here to calibrate 10. Repeat step 9 for each corner of the screen. The calibration utility will automatically advance the cursor to each corner.
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Chapter 4: Troubleshooting the PowerStation Recalibrating the Touchscreen 16. Complete step 9 for each corner of the screen. The calibration utility will automatically advance the cursor to each corner. 17. When you are finished, press the Esc key to return to the calibration main menu.
Chapter 4: Troubleshooting the PowerStation Configuring the Ethernet Interface Configuring the The \NET directory of the PowerStation’s Compact Flash contains a configuration utility and all drivers necessary Ethernet to configure the Ethernet interface on the PowerStation. Interface Backup copies of these files are included on the Machine- Shop Shell Installation Disk.
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Chapter 4: Troubleshooting the PowerStation Configuring the Ethernet Interface File Name Description *NETBIOS.EXE Used by Interact to communicate over a network. RSET8019.EXE Configures interrupts and I/O ad- dresses for the network. TCPIP.EXE Used by the PowerStation for TCP/IP communications. TCPIP.INI Stores settings for TCP/IP communi- cations.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance Performing This section includes instructions for performing internal maintenance on the P1 PowerStation. To prevent injury to Internal yourself or damage to the PowerStation, be sure to read Maintenance and understand the procedures described in this section before performing them.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance • Wear a grounding wrist strap for continuous protec- tion. • Always ground yourself to remove any static charge before you touch the CPU card. • Be particularly careful not to touch the chip connec- tors.
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Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance 5. Remove the two screws securing the touchscreen to the backshell as shown below. Remove these screws 6. Carefully, lift the bottom of the touchscreen approxi- mately two inches while disengaging the tabs that secure the touchscreen to the top of the unit.
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Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance 8. Place the touchscreen face-down on a clean surface to avoid scratching the LCD display. Note If you are replacing the touchscreen or the back- light bulb, you do not need to remove the back cover.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance Replacing DRAM All PowerStations use DRAM that is comparable to that found in most PCs. The size and quantity of DRAM varies depending upon the PowerStation model and the CPU card it uses. However, you can use the same procedure to add or replace DRAM on all models.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance Installing a DRAM module To install a DRAM module, complete the following steps: 1. Place the new SIMM in the DRAM socket at an angle. The notch in the SIMM should be facing the ethernet port, as shown in the figure above.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance 3. To install the new touchscreen, perform steps 6 through 13 of the PowerStation reassembly procedure beginning on page 69 of this manual. Note If you are installing the new touchscreen without removing the unit from its enclosure, skip step 11 of the reassembly procedure.
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Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance 5. Carefully, lift the screen to reveal the display connector as shown below. Display connector Backlight bulb screw 6. Disconnect the display connector by gently pulling on the connector. 7. Remove the screw securing the backlight bulb to the display.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance Installing a PC/104 The PowerStation comes equipped with a PC/104 adapter, which allows you to connect PC/104 I/O cards to the back Card of the unit for communication with the ISA bus. To install a PC/104 card, complete the following steps: 1.
Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance 9. Fasten the PC/104 card cover to the back cover, using the screws provided with the PC/104 adapter kit. Perform any cable connections or further setup required for the PC/104 card before re-installing the PowerStation in its enclosure.
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Chapter 4: Troubleshooting the PowerStation Performing Internal Maintenance 6. Locate pin 1 on the touchscreen plug and align it with pin 1 of the touchscreen connector. The illustration below shows where the touchscreen plug and touch- screen connector are located. A “1” identifies pin 1 on the touchscreen plug.
Chapter 4: Troubleshooting the PowerStation Resolving Common Problems Resolving This section provides some basic troubleshooting steps to help you identify and correct problems you may have with Common the PowerStation. Each problem is described, followed by Problems one or more possible solutions. Begin with the first solu- tion and continue until you have solved the problem or tried all of the solutions.
PowerStation Start Disk. These files are AUTOEXEC.CTC and CONFIG.CTC. The text for AUTOEXEC.CTC appears below: @ECHO OFF REM********************************************* REM PowerStation Autoexec.bat file REM Copyright (c)1999 CTC Parker Automation REM********************************************* PROMPT $p$g SET TEMP=C:\DOS PATH C:\;C:\DOS;C:\CTC REM********************************************* REM Install PowerStation Special Functions if not REM running REM on a P1.
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Chapter 4: Troubleshooting the PowerStation Resolving Common Problems REM********************************************* REM Load VESA TSR if not already supported by the REM video system. REM********************************************* C:\CTC\ISVESA IF NOT ERRORLEVEL 1 GOTO YESVESA LH C:\CTC\VESA :YESVESA REM********************************************* REM Load the MachineLogic Control Adapter driver REM if it is present.
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Chapter 4: Troubleshooting the PowerStation Resolving Common Problems LH C:\NET\TCPIP REM********************************************* REM Load MachineLogic if ML kernel present, and REM set for boot operation. REM (determined by MLDU.EXE return value 0 = REM ENABLED, 1 = DISABLED) REM********************************************* IF NOT EXIST C:\MACHLOG\NUL.EXT MD C:\MACHLOG CD \MACHLOG IF NOT EXIST C:\MACHLOG\MACHLOG.EXE GOTO NOML C:\CTC\MLDU...
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Chapter 4: Troubleshooting the PowerStation Resolving Common Problems REM the HMA to conserve conventional memory. To REM load DOS HIGH use DOS=HIGH,UMB -- otherwise REM use DOS=LOW,UMB. REM DOS=HIGH,UMB DOS=LOW,UMB !!! NOTE !!! REM EEM386 can be used to free up more conventional REM memory for use by MachineLogic and Interact, REM by allowing TSRs to be loaded high.
Chapter 4: Troubleshooting the PowerStation Resolving Common Problems file and overwrite the suspect file with the appropriate backup file. For example, if the AUTOEXEC.BAT file becomes suspect, type the following commands at the DOS prompt: copy autoexec.bat autoexec.old copy \ctc\autoexec.ctc autoexec.bat You cannot edit the AUTOEXEC.BAT or CONFIG.SYS on the PowerStation, but you can do so on your develop- ment PC by pressing Exit on the MachineShop Shell...
Chapter 4: Troubleshooting the PowerStation Resolving Common Problems Make sure that it comes after this line: SET TCHPATH=C:\ATS The LED Power indicator on the front of the unit does not light 1. Check to see whether the power switch is in the On position, and the PowerStation is operating correctly.
Chapter 4: Troubleshooting the PowerStation Resolving Common Problems 4. Check the PC/104 adapter, if one is installed. Remove the adapter, and restart the unit. If the LED comes on, the PC/104 card was bad. Replace the PC/104 card. Resolving Problems This section describes some problems that may occur with the touchscreen and solutions to these problems.
Chapter 4: Troubleshooting the PowerStation Resolving Common Problems 3. Check the touchscreen cable. a. Make sure that the touchscreen cable has been properly connected. Pin1 of the touchscreen plug must be aligned with Pin1 of the touchscreen con- nector. b. Inspect the touchscreen cable for loose, broken, or frayed wiring.
Chapter 4: Troubleshooting the PowerStation Resolving Common Problems 3. The AUTOEXEC.BAT file may be corrupted or may have been modified. See Resolving AUTOEXEC.BAT and CONFIG.SYS problems on page 72 of this manual for information about the command lines that should appear in the AUTOEXEC.BAT file. A PS/2 mouse does not work 1.
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Chapter 4: Troubleshooting the PowerStation Resolving Common Problems See Resolving AUTOEXEC.BAT and CONFIG.SYS problems on page 72 for information about the command lines that should appear in the AUTOEXEC.BAT file. 3. Make sure that you have properly configured the networking software. See Configuring the Ethernet Interface on page 58 of this manual for a list of the drivers that configure your Ethernet interface.
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Chapter 4: Troubleshooting the PowerStation Resolving Common Problems P1 PowerStation User Guide...
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