Service Manual 6200plus Series Chassis 30901-002 December 1999 © 1999 RadiSys Corporation All Rights Reserved Printed in USA
Limited Warranty A. RadiSys Corporation warrants that the item sold by it hereunder will be free from defects in materials or workmanship, under normal use and service, for a period of 2 years from date of shipment. Said item will meet the specifications in effect at the time of manufacture. RadiSys’ sole obligation under this warranty shall be, at its option, to repair or replace, without charge, any defective component of said item, within a reasonable period of time. B.
Important Always use caution when handling or operating the equipment. Only qualified and trained electronics service personnel should access the equipment. Use extreme caution when installing or removing components. For additional information, please contact RadiSys Technical Support at (800) 438-4769 or (713) 541-8200 Monday through Friday between 7:00 a.m. and 6:00 p.m., Central Time, Continental USA. Wichtig Arbeiten am System bzw.
Notice 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 emit radio frequency energy and, if not installed and used in accordance with this instruction manual, may cause harmful interference to radio communications.
Document Conventions Typography Symbols Title Case Bold Title Case Titles of menus, windows, tabs, lists, and groups. Names of menu items, fields, buttons, icons, check boxes, list items, group items, and keystrokes. UPPER CASE Acronyms and abbreviations. Italics Emphasis. Sans Serif Type Items in tables, illustrations, and notations. Monospace Type Output from a printer or monitor. Graphic items will be displayed as an image. Notice: This symbol indicates an item for special consideration.
Customer Support Calling Technical Support Step 1 2 Action Have the RadiSys product model and serial number available. • In the Continental USA, Monday — Friday, 7:00 a.m. — 6:00 p.m., Central Time, dial 1-800-438-4769 in the USA. Outside the USA, dial 713-541-8200 (add long distance/ international access codes). • In Europe, Monday — Friday, 8:30 a.m. — 5:00 p.m., dial +31-36-5461072. Returning Products for Service Step 1 2 Action Have the RadiSys product model and serial number available.
Table of Contents Chapter 1 Operations 1 User-Accessible Features ................................................................................. 2 Specifications .................................................................................................... 5 Chapter 2 Service 7 Accessing the Interior ........................................................................................ 8 Internal Features .....................................................................................
List of Figures 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 vii Front Features ....................................................................................................................3 Rear Features .....................................................................................................................4 Dimensions .........................................................................................................................6 Removing the Top Cover ..........
1 Operations This chapter discusses functions and features of the equipment that can be accessed by all users, regardless of training or skill level. The material contained in this chapter discusses only user-accessible parts and/or operations. This chapter discusses the primary features of the 6200plus series chassis. If you are familiar with the primary components and functions of the 6200plus, go to Chapter 2, “Service,” page 7. Then read this chapter later at your convenience.
Operations User-Accessible Features Overview The 6200plus series chassis provides features that permit great flexibility. This chassis presents a highly configurable solution with exceptional performance. Models The 6200plus is available in three (3) mounting systems: • Benchtop • Rack-mount • Tower For more information on model components, see page 28.
Operations Figure 1 Front Features Note: This illustration shows components for dual hot-swappable power supplies and a split backplane system. For more information, see the Power Supply and Passive Backplane Addenda. 1. 2. 3. 4. 5. 6. 7. 8. 9. Airflow Vents Chassis Body Top Cover Air Filter Compartment Media Drawer 5¼” Drive Bays (4) 3½” Floppy Drive Media Drawer Handle Control Area Door Service Manual A. B. C. D. E. F. G. H. I. J.
Operations Figure 2 Rear Features Note: This illustration shows components for dual hot-swappable power supplies and a split backplane system. For more information, see the Power Supply and Passive Backplane Addenda. 1. 2. 3. 4. 4 Airflow Vents Chassis Body Top Cover Expansion Slots (20) 5. 6. 7. 8. Serial Port Access (SBC 1) Parallel Port Access (SBC 1) AT Keyboard Connector (SBC 1) Power Supply Bay 6200plus Series 9. Serial Port Access (SBC 2) 10. Parallel Port Access (SBC 2) 11.
Operations Specifications Overview Listed in the table below are the specifications for the 6200plus series chassis. Note: These specifications are subject to change without notice. Environmental Environmental tolerances are listed in the following table: Temperature Humidity Shock Vibration Altitude System Operating 0 to 45 °C (32 to 113 °F) 5 — 95% @ 40 °C, non-condensing 1 G @ 10 ms 0.
Operations Figure 3 1.365 17.110 0.000 10.301 5.086 0.000 Dimensions 19.186 0.000 2.020 5.645 9.270 12.895 16.996 17.821 19.010 18.060 0.950 0.000 0.000 19.101 10.460 8.980 6.730 Tower Base 3.730 1.480 0.000 A Note on Thermal Specifications The technology and power density of the microprocessor is rapidly increasing. The 80386 required less than a few hundred milliampere of current. The 80486DX4 peaked at less than 1.5 A and dissipated less than 5 watts of power.
2 Service This chapter discusses functions and features of the equipment that can be accessed only by qualified and trained electronics service personnel. The material contained in this chapter does not discuss any user-accessible parts or operations. All tasks related to material in this chapter must be referred to qualified service personnel.
Service Accessing the Interior Safety It is important to protect yourself and your equipment. Only qualified, experienced electronics service personnel should access and handle the equipment. Es sollte nur qualifiziertes und erfahrenes Fachpersonal am System arbeiten. To avoid damage or injury, always power-off the system and disconnect all power cords from their source before handling the equipment.
Service Figure 4 Service Manual Removing the Top Cover 6200plus Series 9
Service Internal Features Overview The 6200plus series chassis is designed to be flexible yet practical. The interior of the chassis allows easy access to components and peripherals. Passive Backplane The 6200plus provides up to twenty (20) expansion slots with a variety of passive backplanes, presenting a broad assortment of ISA and PCI slot configurations. The 6200plus also supports single or dual SBC operations utilizing a split backplane configuration.
Service Figure 5 1. 2. 3. 4. Internal Features I/O Panel with 20 Expansion Slots Passive Backplane Tray Backplane Mounting Posts (17) Cable Access Holes (4) Service Manual 5. 6. 7. 8. Speaker (SBC 1) Speaker (SBC 2) Electrical Grounding Post Card Guide Bracket 6200plus Series 9. 10. 11. 12.
Service Expansion Cards Installation Before installing expansion cards into the 6200plus series chassis, consult the documentation provided with each card. Follow the manufacturer’s instructions for installing the card. Card Guide A full-length expansion card will reach from the expansion slot at the I/O panel of the chassis to a card guide mounted on the card guide bracket. The card guide reduces lateral movement that can dislodge the expansion card.
Service Figure 6 Expansion Card Guide Bracket Figure 7 Expansion Card Guides BP18-C2P6 Passive Backplane Service Manual BP18S-C2P3 Split Passive Backplane 6200plus Series 13
Service Figure 8 Expansion Card Retention Bracket 1. Retention Bracket (Wide End) 2. Retention Bracket (Narrow End) 14 3. Bracket Mount (Wide End) 4. Bracket Mount (Narrow End) 6200plus Series 5. Card Retention Cushion 6.
Service Figure 9 Service Manual Installing the Expansion Card Retention Bracket 6200plus Series 15
Service Drives and Media Overview The following media can be installed in the 6200plus chassis: • User-accessible drives • Four (4) 5¼” x 1.72” drives • One (1) 3½” x 1” drive, typically a floppy disk drive • Internal drives • Two (2) 3½” x 1” drives, or • One (1) 3½” x 1.6” drive The chassis is designed to accommodate all conventional devices such as fixed and floppy disk drives, CD-ROM or tape drives, etc.
Service Figure 10 Service Manual Removing the Media Drawer 6200plus Series 17
Service Drives and Media (continued) 3½” Drives The media drawer contains a removable bay for 3½” drives. The following media can be installed in this bay: • One (1) user-accessible 3½” x 1” drive, typically a floppy disk drive • Two (2) 3½” x 1” drives, or one (1) 3½” x 1.
Service Figure 11 Service Manual Removing the 3½” Drive Bay 6200plus Series 19
Service Figure 12 20 Installing Drives 6200plus Series Service Manual
Service Fan Tray Overview The 6200plus provides a fan tray with three (3) 90 CFM cooling fans. The fan tray is removable and can be serviced with minimal time and effort. Fan Tray The fan tray is housed in a compartment behind the front panel. The tray is held in place within the chassis by rails on the card guide bracket. This creates a bulkhead between the fan compartment and the passive backplane compartment.
Service Figure 13 1. 2. 3. 4. 5.
Service Figure 14 Fan Tray Interconnect Board Fan Fan Ground 1 Figure 15 Service Manual Fan 12 VDC 4 4 1 Connecting the Fans 6200plus Series 23
Service Air Filter Overview The primary airflow intake for the 6200plus chassis is through the vents in the front panel. Behind these vents is an industrial air filter. Installation The air filter is contained in a compartment behind the filter cover on the front panel. Note: The air filter cover holds the air filter in the compartment.
Service Figure 16 Service Manual Air Filter Installation 6200plus Series 25
Service Power Supply Overview The 6200plus series chassis supports several power supply configurations: • A single PS/2 AC or DC power supply • A power supply enclosure with up to two (2) AC or DC independently redundant, hot-swappable power supplies Note: If only one (1) power supply is installed, a blank panel covers the empty bay.
Service Figure 17 Power Supply Indicators and Controls 1. 2. 3. 4.
Service Model Components Overview The following components accompany each model of the 6200plus chassis (Figure 18): • Feet for the benchtop model • Handles with mounting brackets for the rack-mount model • A base for the tower model Screws for mounting components to the sides of the chassis should not exceed maximum .5” (12.7 mm), nominal .375” (9.525 mm). Screws longer than this can extend inward beyond the chassis walls and damage components installed inside.
Service Figure 19 Installing the Rack-Mount Components Installation notes for rack mount and/or enclosed operation 1) Elevated Operating Ambient Temperature: When the 6200plus chassis is installed in a closed or multi-unit rack assembly, care should be taken to insure that the cooling air supply is sufficient to maintain the the operating ambient temperature at or below 45 degrees C.
Service Figure 20 Installing the Tower Components Circuit overloading: When connecting the equipment to the AC circuits, the circuits should be sized to safely provide all the amperage required by the all the equipment in the rack-mounted enclosure. At a minimum, the supply circuit should be capable of providing amperage equal to the sum of all the rating plate amperages of the equipment contained in the rack/enclosure, plus 20-25% to provide for inrush current peaks.
Service Figure 21 Installing the Tower Foot Figure 22 Removing the Tower Cover Service Manual 6200plus Series 31
Service Notes 32 6200plus Series Service Manual
