Table of Contents Chapter 1 Getting Started ......1 Documentation Components ....... . 2 Documentation Standards .
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Table of Contents Cable diagrams ..........17 Connecting to a PC .
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Table of Contents System Information..........39 Port Usage .
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Table of Contents Chapter 5 Maintaining and Troubleshooting the PowerStation ....... 55 Reformatting the Compact Flash .
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Table of Contents Resolving Problems After Powering the Unit ......78 Resolving problems with the touch screen......78 Resolving other problems after power up .
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Table of Contents P2 PowerStation User Guide...
C h a p t e r 1 G e t t i n g S t a r t e d Thank you for purchasing a P2 PowerStation. The PowerSta- tion is a rugged, compact PC that is designed to be used as an industrial operator interface.
Documentation Components Documentation Components The P2 PowerStation documentation set contains all the information you need to configure, install, and use the PowerStation. It also contains infor- mation about the PowerStation Shell Utility and the Interact Project Manager. The P2 PowerStation documentation set is described below. Release Notes—This document is provided whenever there is important information about the PowerStation that does not appear in this manual.
Documentation Standards Documentation Standards As you read this manual, you will notice that the following documentation standards have been followed. 1. Important terms are shown in bold. 2. Text to be entered from the keyboard is shown in Courier font. 3.
Software Components Software Components CTC pre-loads each PowerStation with the operating system, utilities, and Interact software, so you can run the PowerStation immediately upon its arrival at your facility. CTC also provides source disks for this software should you need to reinstall it at a later time. This section describes each disk and its use.
Important Concepts Important Concepts Now that you have opened the PowerStation package, you are ready to unpack the unit, configure it, and install it in a permanent location. This section provides an overview of the steps that are discussed in detail throughout the remainder of this manual.
Important Concepts Develop an Interact Application The P2 PowerStation is designed to run applications you create using CTC’s Interact application development software. The P2 PowerStation is a runtime-only system, which means you must develop applications on a PC and download them to the PowerStation. Important Throughout this manual all references to ‘development PC’...
Customer Support Services Customer Support Services CTC welcomes your thoughts and suggestions on our products and services. You can contact CTC by telephone, email, or fax. You can also visit CTC on the World Wide Web to learn the latest about CTC hardware, software, and customer support services.
Customer Support Services Technical Support Products Our Technical Support Products department provides service in two areas: training and consulting. CTC offers training on all our products either at CTC 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 interface application.
C h a p t e r 2 U n d e r s t a n d i n g t h e P o w e r S t a t i o n The P2 PowerStation is designed to give you an operator inter- face solution that is powerful, cost-effective, and very easy to use.
Specifications Specifications This section lists and describes some important specifications relating to the PowerStation. Please familiarize yourself with these specifications prior to operating the PowerStation. Physical Specifications Physical specifications include the PowerStation’s physical characteristics and compatible hardware devices. Refer to the table below: Category Specifications CPUs...
Specifications Environmental Specifications The PowerStation conforms to the environmental specifications listed in the table below: Category Specifications Operating 32 to 122 F (0 to 50 C) ambient air tem- Temperature: perature at air inlets Bulb Life: • Monochrome LCD - 10,000 hours •...
Specifications Electrical Specifications The PowerStation’s electrical specifications appear in the table below: Category Specifications Input 20–36 VDC Voltage Power 42W maximum (54W maximum with PC/104) Consumption Fuse Type 3.15A, 250 VAC Littelfuse 216.315 or equivalent PC/104 Power 1.5A@5V, 0.2A@12V; 75mA@-5V, 75mA@-12V Availability Important The PowerStation’s power supply automatically detects the input voltage level and adjusts accordingly.
Available Connectors All PowerStation surfaces exposed to the outside of your enclosure are resistive to the following chemicals: • Commercial glass cleaners • Ammonia (10% dilute solution) • Motor Oil • Hydraulic fluid • Diesel fuel • Gasoline (leaded, unleaded) •...
Available Connectors Serial Ports The PowerStation has two serial ports you can use to communicate with external devices. These ports support baud rates of up to 115 Kbaud. COM1 supports RS-232, while COM2 supports RS-232, RS-422, and RS- 485 communication standards. The communication standard you select for COM2 depends on the distance between the PowerStation and the controller as well as the communication standards that the controller supports.
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 or RS- 422 protocols, you must change the COM2 jumper settings.
Available Connectors Cable diagrams The following graphics represent the pinouts and cable diagrams required for communicating with COM1 or COM2 using the RS-232 protocol. Also shown are cable diagrams for communicating with COM2 using the RS- 422 or RS-485 protocols. RS-232 RS-422 RS-485...
Available Connectors Connecting a serial mouse If you need to connect a mouse to the PowerStation, you must use a serial mouse connected to either COM1 or COM2. If you use COM2, you may need to reconfigure this port to use the RS-232 protocol (see page 71). Follow these steps to configure the PowerStation to use a serial mouse: 1.
Available Connectors During the download, IPM transfers the AUTOEXEC.BAT file you created in step 1 into the \STARTUP directory specified by the INTERACT_STARTUP environment variable. This environment variable resides in the PowerStation’s AUTOEXEC.BAT. When IPM finishes the download, the PowerStation automatically reboots, and MODE.COM configures the COM port to the required baud rate.
Available Connectors Parallel Port The PowerStation parallel port (LPT1) pinout is identical to the standard IBM parallel printer port. The LPT1 connector pinout is shown in the table below. Pin # Signal Name STROBE DATA 0 DATA 1 DATA 2 DATA 3 DATA 4 DATA 5...
Available Connectors Keyboard Port The PowerStation’s CPU board includes a mini-DIN keyboard port. This port can accept input from keyboards that have a PS/2 connector. This port can also accept input from IBM AT-compatible keyboards, including 84- key standard keyboards and 101-key enhanced keyboards, using the supplied keyboard adapter cable.
Available Connectors Compact Flash The PowerStation has a Compact Flash (CF) card that is like a removable hard drive. It provides non-volatile memory storage. The CF is often used as a supplement to or a replacement for hard drives because it is well-suited for environments where the PowerStation may be vibrated or shaken.
Drive Definitions and Memory Map Drive Definitions and Memory Map This section provides information about the PowerStation’s drive defini- tions. This section also includes a graphical illustration of the PowerSta- tion’s memory map. Drive Type Size Usage Letter Compact 4, 10, 20, or System boot drive and Project Flash (CF) 40MB...
Jumper Settings Memory Guidelines Refer to the memory guidelines listed below when you develop projects. The following table lists guidelines to follow concerning the use and capacity of memory used for runtime and development systems. Memory Type Runtime System DRAM 4 MB system memory runs APM, PTM, and AMM runtime modules and 2 drivers.
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Jumper Settings This set of jumpers is used to configure the hardware IRQ for the touch screen. The touch screen IRQ jumpers are located at the lower left corner of the Ethernet/Power Supply board, just beneath the CPU card. CTC Parker configures these jumpers to use IRQ 11. IRQs To change these jumpers, you may need to remove the CPU card.
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Jumper Settings The touch screen jumpers are set to I/O address COM3 (3E8h) with the A jumper “on” and the B jumper “off” by default.The touch screen could also be configured to the COM4 (2E8h) address by turning the A and B jumpers “on,” as demonstrated below. Important After changing the jumper settings for the touch screen I/O address, you must change the touch screen configuration drivers for the Configuring the Touch Screen...
Using a Touch Screen with Interact Using a Touch Screen with Interact If you are using a touch screen with Interact and your application uses PTM Slide input tools, be sure to select the Arrow cursor type using the Interact Settings command in Application Manager. When you select the Arrow cursor type, touching the Slide tool selects the tool, and moving your finger over the touch screen moves the slide knob.
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Interact Startup Directory P2 PowerStation User Guide...
C h a p t e r 3 U s i n g t h e P o w e r S t a t i o n S h e l l U t i l it y Now that you are familiar with some of the PowerStation’s features, it’s time to configure your system.
Introduction Introduction Prior to using the PowerStation you should understand the features avail- able with the PowerStation Shell Utility. The PowerStation Shell comes pre-installed on your system. However, if you need to reinstall the Shell software or the touch screen drivers, you can use the PowerStation Shell Setup disk.
Selecting Screen Options Selecting Screen Options To select screen options, touch the menu item or move the cursor over the menu item you want to select and press the left mouse button. A submenu of options appears that you can change for this menu item. Upon selecting a submenu, you can return to the previous menu by: •...
Menu Definitions Menu Definitions This section provides a description of each item on the Shell Main Menu and the function of each selection button. Main Menu When you power up the PowerStation, the Shell performs an internal check of the configuration settings for the unit and displays the Shell Main Menu as shown below.
Menu Definitions Name Description APPLICA- Displays a list of applications in the project that were TIONS created in Interact or copied from another project. Help On Shell Select the HELP ON SHELL button to enter the Shell help system. To request help on a menu button or option, move the cursor to the function and press the F1 key on the keyboard.
Menu Definitions Configuration Settings Select the CONFIG SETTINGS button to change the PowerStation hard- ware settings. Once assignments have been made, they are stored in the PWR.CFG file on drive C. Important The hardware configuration settings stored in the PWR.CFG file are saved on drive C (flash disk).
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Menu Definitions TOUCH SCREEN The TOUCH SCREEN option automatically detects and displays the port where the touch screen is connected if your PowerStation is configured to use a touch screen. This port setting is displayed for informational purposes and cannot be changed through the Shell. DOWNLOAD ENABLE Use the DOWNLOAD ENABLE option to select which of the installed serial ports can be used for downloading projects to the...
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Menu Definitions SERIAL PORT IRQS Use the SERIAL PORT IRQS option to select the communication port IRQ. In order for the Shell to use the installed serial ports for down- loading and for touch screen operation, the Shell must have knowledge of the hardware IRQ numbers used by each serial port.
Menu Definitions SET BRIGHTNESS/SET CONTRAST Use these options to change the brightness and contrast levels of your display. When you select either one of these options, a popup menu will display Increase/Decrease options. Each click on a selection will increase or decrease the brightness or contrast by one level. Note Not all display types support Brightness and Contrast adjustments.
Menu Definitions Touch Screen Calibration Select the SCREEN CAL button to launch the touch screen calibration utility. When you select this button, the following message appears: Important The touch screen calibration utility requires you to use an external Keyboard Port keyboard.
Menu Definitions System Information Select the SYS INFO button to provide information on system resources such as the Shell version number, processor type, installed memory, etc. Use this information to assist you during PowerStation configuration. This information will be requested whenever you contact CTC’s Product Tech- nical Support department for assistance.
Menu Definitions Port Usage Select the PORT USAGE button to view the port memory assignments for the PowerStation. An example of this window appears below. Your screen may differ from this one based on your hardware configuration. Memory Map Select the MEMORY MAP button to display the memory map of the PowerStation.
Menu Definitions Go To Interact Select the GO TO INTERACT button to execute Interact from the Shell. Doing so provides the proper environment for Interact to create and use the applications within the currently selected project. The Interact module displayed is determined by the project’s Startup Application configuration setting in the Application Manager.
Menu Definitions Use this option to display a list of all files and directories on the PowerSta- tion. Select the desired drive letter and directory to display the files in that directory. The directory path is listed at the top of the screen. The number of files, the total number of bytes in this directory, and the total number of bytes remaining on this drive are listed at the bottom of the screen.
Menu Definitions System Tests Select the SYSTEM TESTS menu to display a submenu of tests that you can perform on the PowerStation. At this time, you can perform a keyboard test by pressing the KEYBOARD TEST button. Keyboard Test Select the KEYBOARD TEST button to begin the keyboard test. When you press a key, the PowerStation will display the text string that matches that key.
Reinstalling the Shell Software Reinstalling the Shell Software The PowerStation Shell comes pre-installed on the PowerStation’s compact flash (CF) card. This section explains the procedure to reinstall the Shell software onto a formatted and bootable CF card. If you need to reformat the CF card, see Reformatting the Compact Flash on page 56.
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Reinstalling the Shell Software 3. Insert the CF card into the PC’s PCMCIA slot, using the CF-to-PCM- CIA adapter. The PCMCIA drivers should recognize and configure the card as an ATA card, assigning an additional drive letter for the card (e.g., D:). In this example, drive D: represents the PCMCIA card;...
Recalibrating the Touch Screen 8. Press N when you are asked if you want to recalibrate the touch screen. The PowerStation Shell installation is complete. 9. Eject the CF-to-PCMCIA adapter, and remove the CF from the adapt- The CF card is now ready to use in the PowerStation. Important Always make sure power to the PowerStation is turned OFF when inserting or removing the CF card.
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Recalibrating the Touch Screen 2. Press any key when you are ready to begin the calibration program. The following screen appears: 3. Press C for Calibration. When the next screen appears, you will be cal- ibrating video mode 80 x 25 Text (2,3). 4.
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Recalibrating the Touch Screen 18. Press Esc or X to exit. Important After calibrating the touch screen, enter Interact in Program Mode. Verify that the cursor appears on the screen where you touch, other- wise recalibrate the screen. The calibration MUST be accurate to avoid activating a button unintentionally during Run Mode.
C h a p t e r 4 I n s t a l l i n g t h e P o w e r S t a t i o n When you finish configuring the PowerStation, you can begin making preparations to install the unit in a permanent location.
Selecting a Location Selecting a Location The first step to installing the PowerStation is to select an appropriate loca- tion for the unit. This is the most important aspect of the installation because the location you select can affect the PowerStation’s performance, ease-of-use, life-expectancy, and more.
Selecting a Location Electrical Guidelines To minimize unwanted electrical interference, select a location away from machinery that produce intense electrical noise. If this cannot be avoided, isolate input power to the unit and separate all data communication cables used with the unit from AC power lines. See Electrical Specifications on page 12 for a list of electrical specifica- tions.
Creating the Cutout Creating the Cutout Once you have selected a location, you can begin preparing it to accept the unit. Prior to installing the PowerStation, you will need to create a cutout for the unit and clean the area of any dirt or debris that may come in contact with the unit.
Installing the Unit Installing the Unit Once you have prepared the mounting location for the PowerStation and the AC power supply (if purchased), you can begin installing the unit. Mounting the Unit Once the mounting surface has been prepared, you can install the Power- Station.
Powering Up the Unit Powering Up the Unit Once the unit has been mounted, you are ready to power up the unit. This procedure appears below. Before connecting a power cord to your unit, make sure you have read and understand the following sections of this manual: Electrical Specifications on page 12 and Testing Specifications on page 13.
C h a p t e r 5 M a i nt a i n i n g a n 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 PowerStation has been designed to provide years of trouble-free operation even in the harshest environments.
Reformatting the Compact Flash Reformatting the Compact Flash This section explains the procedure to create a bootable Compact Flash (CF) card for the PowerStation from a “blank” CF card. This procedure may be necessary if certain critical files are deleted or corrupted on the card or to prepare a new card for use.
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Reformatting the Compact Flash 3. Insert the CF card into the PC’s PCMCIA slot, using the CF-to-PCM- CIA adapter. The PCMCIA drivers should recognize and configure the card as an ATA card, assigning an additional drive letter for the card (e.g., D:) In this example, drive D: represents the PCMCIA card;...
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Reformatting the Compact Flash 11. At the DOS prompt, type the following command sequence: A:INSTALL A: D: 12. Press Enter to execute this command. This will install the PowerStation Shell files and necessary drivers onto drive D (or the drive assigned to the CF card in the PCMCIA slot).
Modifying the AUTOEXEC.BAT File Modifying the AUTOEXEC.BAT File The following lines must appear in the AUTOEXEC.BAT file for proper operation of the PowerStation. The AUTOEXEC.BAT file that CTC supplies includes these lines and is located in the \CTC directory of the PowerStation in a file called AUTOEXEC.CTC.
Configuring the Touch Screen Drivers Configuring the Touch Screen Drivers The C:\TOUCH\DOX\SC3DOX.EXE file is needed to configure the touch screen in MS-DOS. This file initialized the touch screen driver. Important If you purchased a PowerStation with the touch screen disabled and you want to enable it, remove the REM statement that appears at the beginning of the above line.
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Configuring the Touch Screen Drivers 3. Press I for Interface. The following Interface Configuration Options screen will appear. 4. Press I to change the Interrupt or press 1, 2, 3 or 4 to change the COM port. Note If you use Set COM3 or COM4, they will default to COM1 and COM2 IRQs.
Configuring the Ethernet Interface Configuring the Ethernet Interface The \NET directory of the PowerStation’s flash drive contains a configu- ration utility and all drivers necessary to configure the Ethernet interface. CTC also includes backup copies of these files on the PowerStation Shell Installation Disk.
Performing Internal Maintenance/Upgrades Performing Internal Maintenance/Upgrades This section includes helpful information for performing internal mainte- nance on the PowerStation. To prevent injury to yourself and/or damage to the PowerStation, be sure to read and understand the procedures found in this section before performing the procedures. This section will show you how to perform the following operations: •...
Performing Internal Maintenance/Upgrades Disassembling the PowerStation If you have read and understand the ESD safety precautions, you are ready to disassemble the PowerStation. Follow these steps to disassemble the unit: Important As you begin to disassemble the unit, you will encounter several different screw sizes.
Performing Internal Maintenance/Upgrades Adding and Replacing DRAM All PowerStations use DRAM that is comparable to what is found in most PC’s. The size and quantity of DRAM varies depending on the PowerSta- tion model and the CPU card. However, the same procedure applies to add and replace DRAM on all models.
Performing Internal Maintenance/Upgrades Installing a DRAM module Follow these steps to install a DRAM module. 1. Carefully insert the DRAM module into its socket at a 45-degree an- gle. The notch on the bottom of the DRAM module should align with the ridge on the socket.
Performing Internal Maintenance/Upgrades Safety Precautions Observe normal precautions against electrostatic discharge (ESD) to prevent damage to your PowerStation or to your adapter boards. Anyone handling internal components should do so only in an ESD-safe location and should use appropriate grounding methods. To avoid electric shock, always disconnect power from the unit before you remove the backshell cover or separate the backshell from the front panel.
Performing Internal Maintenance/Upgrades Changing the Jumper Settings The PowerStation has three sets of jumpers located on the Ethernet/Power Supply board that you can change, if necessary. The first set of jumpers (JP1) allows you to restore the Ethernet port to a known configuration of IRQ 10 and I/O address 240H.
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Performing Internal Maintenance/Upgrades these jumpers, you may need to remove the CPU card. This procedure is described below. Removing the CPU card CTC does not recommend removing the CPU card; however, you may need to do so to change the jumper settings for the touch screen IRQ. The following procedure describes how to remove the CPU card: 1.
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Performing Internal Maintenance/Upgrades 7. Re-install the CPU card by performing steps 1–5 in reverse order. JP7 Touch screen address These sets of jumpers configure the address for the touch screen. It is configured by turning “on” or “off” the ports A and B. Use the following chart to determine the on/off combination for the port to which you would like to configure: COM1, COM2, COM3, or COM4.
Performing Internal Maintenance/Upgrades COM2 jumpers CTC configures the COM2 serial port for RS-485 communications; however, you can configure this port to communicate using RS-232 or RS- 422 by changing the jumper settings on the CPU card. To configure COM2 to use RS-232, move the clip to the RS-232 position and move the COM2 cable from RS-422/485 connector to the RS-232 connector.
Cleaning the Touch Screen Cleaning the Touch Screen Occasionally, you might find it necessary to clean the touch screen of the PowerStation. Clean the touch screen using warm soapy water and a cloth. You may also use any non-abrasive cleaner. See Faceplate Chemical Resistance on page 13.
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Resolving Common Problems Resolving problems with the touch screen • After power up, the touch screen does not work properly, or the touch screen calibration appears to be incorrect (page 78) • After calibrating the touch screen, it either does not work or follow your finger (page 79) Resolving other problems after power up •...
Resolving Common Problems Resolving Problems When Powering the Unit One of the most common problems that users encounter with PCs occurs while booting up their system. This section describes some possible prob- lems and solutions for booting up the PowerStation. Resolving AUTOEXEC.BAT and CONFIG.SYS problems Some bootup problems are caused by a corrupted or modified...
Resolving Common Problems REM ********************************************************* IF EXIST C:\STARTUP\AUTOEXEC.BAT CALL C:\STARTUP\AUTOEXEC.BAT REM ********************************************************* REM Uncomment next statements to load NOVELL network batch file REM ********************************************************* REM CD \NET REM CALL C:\NET\NET.BAT REM ********************************************************* REM Start the CTC Shell REM ********************************************************* CD \CTC The text for CONFIG.CTC appears below: ;MS-DOS V6.22, ROM-DOS 6.22 Rev 2.60 FILES=30...
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Resolving Common Problems 3. Turn on the PowerStation. If the fan does not come on, continue with step 4. 4. Disconnect the PowerStation from its power source. 5. Remove the PowerStation’s back cover. 6. Check the fuse located on the internal power supply. If the fuse is blown, replace it.
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Resolving Common Problems 6. Make sure that all boards are firmly seated. 7. Secure the PowerStation’s back cover. 8. Connect the PowerStation to its power source. 9. Turn on the PowerStation. During power up, the RAM test fails, or the total memory installed does not match the total contiguous RAM listed on the display follow- ing the RAM test 1.
Resolving Common Problems Resolving Problems After Powering the Unit This section lists some possible problems and solutions that may occur after you power up the PowerStation. This section is divided into three sub-sections, one for touch screen problems, one for Interact problems, and one for other problems.
Resolving Common Problems After calibrating the touch screen, it either does not work or follow your finger 1. Make sure the touch screen cable has been properly connected. If the touch screen cable is damaged, replace the touch screen. Contact CTC for information about purchasing a replacement.
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Resolving Common Problems A serial mouse does not work 1. Make sure that the mouse is properly connected to the serial port. 2. If you have connected the mouse to COM2, verify that it is configured for RS-232 communications. See COM2 jumpers on page 71 to change the communications protocol for this port.
Resolving Common Problems Resolving problems with Interact This section lists some possible problems and solutions that may occur on a PowerStation that is running Interact. After power up, the DOS prompt is displayed instead of the PowerSta- tion Shell Main Menu 1.
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Resolving Common Problems You are unable to communicate with the PowerStation’s COM ports 1. Refer to the Interact device driver Program Mode screen of the driver being used to determine if the driver is correctly setup. 2. Verify that the communication cable is wired properly. 3.
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Resolving Common Problems Sending a project results in a message on the display indicating the ????.FIL could not be found You must use a Project developed using Interact version 2.1 or higher on a PowerStation. Previous versions of Interact do not have the .FIL file. A message appears on the PowerStation stating that the disk is full Verify that Interact Project Manager is set to download to a Runtime Only system.
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Resolving Common Problems The code <00> appears on the display during Super User mode Reboot the PowerStation and return to the Shell or type exit to return to the Main Menu. This indicates that a communication problem on the computer occurred. Verify that Interact Project Manager was only executed once.
Index CPU Manual 2 CPUs 10 AC power supply 52–53 CRT port 19 address/IRQ considerations 67 Customer Support Services 7 altitude 11 applications, downloading 6 AUTOEXEC.BAT data storage methods 10 command line parameters 59, 74 dimensions 10, 85 troubleshooting 74, 78 disks See utility disks display types 10...
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Index considerations 50 Go To Interact 41 rating 11 Help On Shell 33 fuse type 12 System Info 39 System Tests 43 Utility Menu 41 MODE.COM 18 I/O ports 10 Monochrome LCD display 10–11 important concepts 5 mouse port input voltage 12 See serial ports, connecting a serial installation mouse...
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Index internal maintenance 63 Shell IRQs 67 Main Menu 32 memory map 23 menu definitions 32 power up 30, 54 selecting screen options 30 reassembly 71 Shell Main Menu release notes 2 Config Settings 34 specifications 10 DOS Shell 43 template 2 Exit Shell 42 troubleshooting 72...
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Index utility disks 4 weight 10 P2 PowerStation User Guide...
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