FR202

FR202 Product Manual

Revision History

1- System Overview

1.1- System Introduction

The Factor 202 (FR202) harnesses the power of the Raspberry Pi Compute Module 4, which provides the core functionality of the Raspberry Pi 4. Combined with our own industry-focused carrier board, and a custom-designed industrial chassis, the Factor 202 has been engineered for today's industrial and embedded applications.

For use as a compact IoT gateway, edge device, or customizable industrial controller, the Factor 202 is the industrial Raspberry Pi solution you've been waiting for.

1.2- In-box Accessories

• 1x Power Terminal Block

• 1x COM Terminal Block

• 7x IO Terminal Block

If you purchased additional items such as mounting brackets, power supplies or terminal block connectors, they will be located in the system box or within the outer shipping carton.

All drivers and product guides can be found on the corresponding product page. For more information on accessories and additional features, visit the Factor 200 Series page.

Factor Series Page: https://www.onlogic.com/store/computers/industrial/fanless/factor-200/ Factor 202 Product Page: https://www.onlogic.com/store/fr202/

1.3- Product Specifications

1.4- Exterior Features and Dimensions

Top I/O

Bottom I/O

Factor 202 Dimensions (FR202)

1.5- System Block Diagrams

2- I/O Definitions

2.1- Top I/O Definition

USB-C Config Port (CM4 Update)

A USB-C port is provided to connect to the CM4 in USB 2.0 device mode, to update the bootloader firmware or modify the eMMC filesystem in USB MSD mode.

A USB 2.0 host used to connect the FR201 must provide a 5V output in order to enable the USB-C connection to the CM4. System power for the FR201 must also be provided separately via the main power input or optional PoE.

USB 3.x, alternate function modes, and power output are not supported on this connector.

HDMI

FR201 uses the CM4’s integrated HDMI to drive the external HDMI Port. Resolutions up to 4096x2304 @ 60Hz are supported. CEC (Consumer Electronics Control) functionality is also supported, depending on software configuration.

USB 3.2 Gen1 5Gb/s

One USB 3.2 Gen1 (5Gb/s) port is provided for peripherals or boot media. By default, this port is disabled during system boot to ensure that the CM4 boots from internal media. This behavior can be changed in software, or via the jumper header located in the center of the motherboard. See the headers section of this manual for more information.

USB 2.0

Two USB 2.0 ports are provided for peripheral usage. Together, they may deliver a maximum of 2A at 5V, depending on peripheral and device configuration.

Reset Button

The front reset button can be used to trigger a reset of the CM4. The reset button is a momentary contact button that is tool-accessible through the chassis.

Digital Inputs

16 optically isolated digital inputs are provided via 2 10-pin terminal block connecters (Dinkle 0221-2010 or equivalent). Performance is optimized for 12-24V operation.

Each group of 4 inputs (DI0-3, DI4-7, DI8-11, and DI12-15) is software-configurable to active-high or active-low. The active-low configuration activates internal pull-ups to the VCC pin of the same header. Customers must connect both VCC and GND of that group’s connector for the IOs to function correctly.

Inputs are active at voltages exceeding 11.5V and inactive below 4.5V.

“Active-Low” / Sinking Output-Compatible Input Wiring

“Active-High” / Sourcing Output-Compatible Input Wiring

Digital Outputs

16 optically isolated digital outputs are provided via 2 10-pin terminal block connecters (Dinkle 0221-2010 or equivalent). Performance is optimized for 12-24V operation. Operating voltage should not exceed 24V. Each output has a 0.5A resettable fuse.

Each group of 4 outputs (DO0-3, DO4-7, DO8-11, and DO12-15) is software-configurable to sourcing or sinking (high- or low-side switched). For all configurations, customers must supply a VCC and GND connection on the same connector as the outputs in use. No power is sourced for the outputs through the system power connector.

Sourcing Output Wiring

Sinking Output Wiring

2.2- Bottom I/O Definition

3-Pin Terminal Block Power Connector

Mainboard power is applied to the FR201 platform by way of a 3-pin terminal block connector (Mating part: Dinkle 2ESSM-03P or equivalent). The system is operational from 8V~24V. The maximum rated current of the connector is 15A per pin. Use a wire gauge that is rated for the operational current. See below for on-board connector pinout. Note: DC power input should not be connected when the system is supplied with POE power via the add-on module.

5-Pin COM Terminal Block

The serial port supports RS-232, RS-422, and RS-485 configurations by way of a 5-pin terminal block connector (Mating part: Dinkle 0221-2005 or equivalent). The mode can be selected from within the operating system using available configuration tools. See FR201 software documentation for details.

LAN1 - CM4 Driven

The CM4 LAN Port on FR201 supports up to 1Gbps link speeds over standard shielded CAT5e or CAT6 cables. The connector is the industry standard RJ45 connector. The LAN link state is shown by the two LEDs enclosed in the port. Activity is also indicated by the LAN1 LED on the side of the system. The default configuration is included below, but the behavior can be customized using the CM4 boot configuration file. PoE PD (power input) support is available optionally by adding the ADP125 FR200 isolated POE PD module to the system. Note: DC power input should not be connected when the system is supplied with POE power via the non-isolated ADP122 add-on module.

LAN2 - Realtek RTL8153B

The second LAN Port on FR201 supports up to 1Gbps link speeds over standard shielded CAT5e or CAT6 cables. The connector is the industry standard RJ45 connector. The LAN link state is shown by the two LEDs enclosed in the port. The description is included below. Activity is also indicated by the LAN2 LED on the side of the system.

Analog/Temperature Inputs

4 analog inputs and two temperature inputs are provided on the two 10-pin headers shown above. Each analog input accepts 0~5V, 0~10V, -5~5V, -10~10V, 0-20mA, 4-20mA, or 4-24mA signals, internally scaled and measured by an ADC connected to the SPI4 bus. Voltage inputs are connected by supplying V+ and GND to the connector from the signal source. Current inputs are connected using I+ and GND. Final values are computed based on software configuration.

An application to configure and use the analog inputs is provided by OnLogic and ships in OnLogic-installed operating systems. Calibration updates can be made in the application by adjusting the scaling factor applied as measurements are computed. For details of use, see the software and firmware documentation section.

Temperature inputs may be connected to 2-, 3-, or 4-wire sensors. Excitation current is supplied between TI+ and TI-, and the sensor input is measured between TV+ and TV-. To connect a 2- or 3-wire sensor, short the appropriate missing wires at the connector (ex. for a 2-wire sensor, connect TI+ to TV+, TI- to TV-, and then connect TV+ and TV- to the sensor). Excitation current is configurable via software, and the temperature must be derived from the voltage measurement based on the performance curve of the sensor connected.

SPI/I2C/UART/RS485 Header (Isolated)

SPI, I2C, and UART/RS485 interfaces not used internally are isolated and exposed on a communications header on the bottom IO face. In the standard configuration, the following interfaces are connected:

• SPI4 (chip select #1)

• I2C6

• UART1

UART1 may also be routed to an onboard RS485 transceiver outputting on the same connector pins. TX/RX control is implemented via Pi/BCM GPIO 17.

Where necessary, internal pull-ups on the SPI and I2C interfaces are provided. Depending on the length and configuration of the external wiring, customers may need to provide additional components for signal conditioning.

Front Display

A 320x240 full-color backlit display with capacitive touchscreen is provided for customer use, for displaying diagnostic or setup information. It can be configured as an additional desktop display using a framebuffer driver or used independently of the operating system graphics system via the SPI3 interface.

A demonstration application with basic diagnostic information is provided as part of OnLogic-supplied operating systems. Example code and additional information is available in the FR200 software documentation.

2.3- Motherboard Connectors

M.2 B-Key

An M.2 B-Key port is present on the FR201 motherboard to allow support for B-Key form-factor expansion cards. Supported cards include 3042, 2242, and 2260 form-factors with an adapter and 2280 form-factor without. The B-Key connector at A14 on the FR201 platform supports SATA Gen I (1.5Gbps), SATA Gen II (3.0Gbps), and SATA Gen III (6.0Gbps) devices. The B-Key connector at A15 on the FR201 platform supports USB 3.2 5Gb/s and USB 2.0 devices.

A full pinout table for this expansion slot is provided in Appendix D.

Boot Function Jumper Header

A 2mm pin header and jumpers are used to configure some CM4 boot settings.

To enable write-protect for the bootloader, short pins 3 and 4 and apply power to the system.

To disable OS boot and place the CM4 in bootloader update mode, short pins 5 and 6 and apply power. The system will wait for a connection from an outside system via the USB-C configuration port in order to perform firmware updates.

RTC Battery Header

The RTC battery on the FR201 platform is used to retain platform settings and maintain the real-time clock for the system. If the RTC battery is low, CMOS settings will not be retained and you may receive an alert in the operating system. The cabled RTC battery should be replaced with a Maxell CR2032-WK11 (or UL listed equivalent). An equivalent battery shall use a Hirose DF13-2S-1.25c connector to mate with the on-board connector.

Raspberry Pi Header

The Raspberry Pi header is used as the main connection between the FR202 IO board and the motherboard. The pinout and description are provided here as a reference.

The Raspberry Pi header is designed to mimic the header on the standard Raspberry Pi 4, with additional features. For a detailed list of standard features that this header supports, see the Raspberry Pi documentation. The connector on the Factor 201 is female, but is pinned such that a developer can install a male-to-male interposer and use it as a standard hat header, if the developer notes the following changes:

1. A USB2.0 connection is added at pins 41 & 42.

2. The header’s I2C connection (typically noted as ID_SC and ID_SD) is changed to the system I2C bus, rather than the Raspberry Pi ID bus.

3. The header’s GPIO16, 18, 20, & 21 connections are shared with the TPM (configured as SPI6 when installed). If TPM support is desired, developers must avoid implementing these pins on the expansion header as well.

DSI Header (Not Populated)

The DSI (MIPI display) header is pinned identically to the Raspberry Pi 4 DSI header, but is not implemented or installed by default, and is not supported at this time.

CSI Header (Not Populated)

The CSI (MIPI camera) header is pinned identically to the Raspberry Pi 4 DSI header, but is not implemented or installed by default, and is not supported at this time.

POE Add-on Connector

The POE PD Add-on connector is designed to support the OnLogic ADP125 POE PD add-on module. Other uses are not supported. See specifications for the ADP125 here

CM4 Headers

The dual-header CM4 connectors support installation of Raspberry Pi CM4 modules. Two mounting standoffs are included to secure the module.

MCU Update Header

A two-pin header is provided to force the DIO controller into bootloader mode. DIO controller updates should be performed by this method only when instructed.

3- Mounting Instructions

DIN Rail Mounting

Step 1 (DIN Bracket only): Align the mounting holes of the din clip bracket to the two mounting holes on the back of the chassis.

Step 2 (DIN Bracket): Mount system onto the DIN rail.

Wall Mounting

Step 1: Align the four screw holes on the bottom of the system with the respective holes on the mounting brackets.

Step 2: Attach wall mounting brackets (MTW101) to the system using the supplied M3 screws (M3X0.5 Flathead Screw, 4mm Long)

Step 3 (Wall Mount only): Install system to surface using keyhole slots on wall mount brackets and appropriate hardware for the surface (not provided).

Note: The mounting brackets are required to support 4x the hanging weight of the system. The mating surface and hardware must be capable of supporting the same load.

4- Power Management

4.1- Protection Circuitry

These DC levels specified are the absolute max values for the pins for function and safety of the system. The protection circuitry allows for brief transient voltages above these levels without the system turning off or being damaged. A transient voltage suppressor on the power input allows momentary excursions above stated limits. For input power consumption and current see Appendix A.

4.2- Input Voltage Qualification

The base FR202 system is capable of operation with an input voltage ranging from 12V - 24V DC, however different configurations will impact total system draw and may limit input voltage flexibility in the final application.

5- Software & Firmware

5.1- Downloads

For downloads see Manuals and Downloads in Raspberry Pi Technical Support.

5.2- Features & Configuration

For features see Factor Features in Raspberry Pi Technical Support

6- Regulatory Compliance

CE

The computer system was evaluated for medical, IT equipment, and maritime EMC standards as a class A device. The computer complies with the relevant equipment directives for the CE mark. Modification of the system may void the certifications. Testing includes: EN 55032, EN 55035, IEC 60601-1, EN 62368-1, EN 60950-1, and IEC 60945. The computer is approved for coexistence of the two provided radio transmitters when used with the specified antennas.

FCC Statement

This device complies with part 15 of the FCC rules as a Class A device. Operation is subject to the following two conditions: (1) this device may not cause harmful interference and (2) this device must accept any interference received, including interference that may cause undesired operation.

ISED

This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes: (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement.

CAN ICES-003(A) / NMB-003(A)

UKCA

The computer system was evaluated for IT equipment EMC standards as a class A device. The computer complies with the relevant IT equipment directives for the UKCA mark.

VCCI

This is a Class A product based on the standard of the Voluntary Control Council for Interference (VCCI). If this equipment is used in a domestic environment, radio interference may occur, in which case the user may be required to take corrective actions.

Regulatory Uploads

7- Appendices

7.1- Appendix A: Power Consumption

The power consumption of the Factor 202 was measured for various system configurations, workloads, and power states at both 12V and 24V system input voltages. The build configurations and power consumption are listed in the tables below.

*The configurations below are using representative samples of internal devices, the specific components mentioned below may vary from the devices provided by OnLogic.

The power consumption for each system configuration is recorded below

7.2- Appendix B: Software Documentation

For a detailed overview of the configuration and individual settings, please refer to the Raspberry Pi Technical Resource Section. Instructions for updating the BIOS and Firmware can also be found in this section.

7.3- Appendix C: System Thermal Results

The thermal performance of the FR202 was validated by loading the system to simulate expected workloads while the test system was exposed to high ambient temperatures in a thermal chamber environment. The test workload was a 4 core load designed to simulate heavy processing. The system was run at 100% load for 45 seconds and then the load was removed for a 15 second rest. In order to profile performance at a variety of thermal conditions, the thermal chamber temperature was raised from 40°C to 60°C with a 4 hour dwell at each 5° increment. The results were analyzed by comparing the average clock speed over the duration of the test to the expected base clock speed. CPU throttling was observed beginning at 50°C, with performance gradually decreasing to just above the maximum throttle state (600 MHz) at 60°C.

FR202 - 4 Core 75% Load Thermal Testing Graph - The image below shows the thermal test results from an FR202 in a thermal chamber with 75% full 4 core workload (45s at 100% followed by 15s rest) over a temperature range from 40-60°C with a 4 hour dwell every 5°C.

FR202 - 4 Core 75% Load Thermal Testing Component Results - the graph below shows the key component temperature values from the above test. The table is the maximum observed temperature and component test limits

7.4- Appendix D: Expansion Port Pinout

M.2 B-Key (MODEM)

M.2 B-Key (SATA)

7.5- Appendix E: Safety Information

Do not open or modify the device. The device uses components that comply with FCC and CE regulations. Modification of the device may void these certifications.

Safe Use and Installation Instructions

1. Install the device securely. Be careful handling the device to prevent injury and do not drop.

2. Wall or ceiling mounting the device requires use of a mounting plate or bracket. The plate or bracket must be of metal construction and have a minimum thickness of 1mm.

3. Use M4x0.5mm Flat Head screws to attach mounting plate or mounting brackets to threaded holes on bottom or rear of chassis. Screws should be a minimum length of 4mm. Add 1mm of screw length for every mm of additional thickness of plate or bracket beyond 1.5mm.

4. Ambient operating temperature must be between 0 °C to 60 °C with a non-condensing relative humidity of 10-90%.

5. The device can be stored at temperatures between -10 °C to 85 °C.

6. Keep the device away from liquids and flammable materials.

7. Do not clean the device with liquids. The chassis can be cleaned with a cloth.

8. Allow at least 2 inches of space around all sides of the device for proper cooling. It is recommended to mount the device such that the metal side plates are vertical to allow air to rise unobstructed. Alternative orientations may result in reduced operational temperature range.

9. This device is intended for indoor operation only.

10. Use only antennas provided. Maintain 20cm of distance from the antenna.

11. Use UL Listed external power supply with rated output 12Vdc

12. Install the device only with shielded network cables.

13. Only use SAE approved cables for automotive installation.

14. The installer should be experienced in aftermarket installation and familiar with general practices for installing electronics devices in vehicles.

15. The device should not be installed in the driver’s area of a vehicle.

16. The device should be mounted in accordance with accepted aftermarket practices and materials for vehicle installation.

17. Only use UL Listed connectors for power and serial.

18. Service and repair of the device must be done by qualified service personnel. This includes, but is not limited to, replacement of the CMOS battery. Replacement CMOS battery must be of the same type as the original.

19. Proper disposal of CMOS battery must comply with local governance.

WARNING: There is danger of explosion if the CMOS battery is replaced incorrectly. Disposal of battery into fire or a hot oven, or mechanically crushing or cutting of a battery can result in an explosion.

Instructions d'utilisation et d'installation en toute sécurité

1. Installez l'appareil en toute sécurité. Manipulez l'appareil avec précaution pour éviter de vous blesser et ne le laissez pas tomber.

2. Le montage mural ou au plafond de l'appareil nécessite l'utilisation d'une plaque ou d'un support de montage. La plaque ou le support doit être en métal et avoir une épaisseur minimale de 1 mm.

3. Utilisez des vis à tête plate M4x0,5 mm pour fixer la plaque de montage ou les supports de montage aux trous filetés au bas ou à l'arrière du châssis. Les vis doivent avoir une longueur minimale de 4 mm. Ajoutez 1 mm de longueur de vis pour chaque mm d'épaisseur supplémentaire de plaque ou de support au-delà de 1,5 mm.

4. La température ambiante de fonctionnement doit être comprise entre 0 °C et 60 °C avec une humidité relative sans condensation de 10 à 90 %.

5. L'appareil peut être stocké à des températures comprises entre -10 °C et 85 °C.

6. Gardez l'appareil à l'écart des liquides et des matériaux inflammables.

7. Ne nettoyez pas l'appareil avec des liquides. Le châssis peut être nettoyé avec un chiffon.

8. Laissez au moins 2 pouces d'espace autour de tous les côtés de l'appareil pour un refroidissement correct. Il est recommandé de monter l'appareil de manière à ce que les plaques latérales métalliques soient verticales pour permettre à l'air de monter sans obstruction. Des orientations alternatives peuvent entraîner une plage de températures de fonctionnement réduite.

9. Cet appareil est destiné à une utilisation en intérieur uniquement.

10. Utilisez uniquement les antennes fournies. Maintenez une distance de 20cm avec l’antenne.

11. Utilisez une alimentation externe homologuée UL avec sortie nominale 12 Vdc

12. Installez l'appareil uniquement avec des câbles réseau blindés.

13. Utilisez uniquement des câbles approuvés par SAE pour une installation automobile.

14. L'installateur doit avoir de l'expérience dans l'installation du marché secondaire et être familiarisé avec les pratiques générales d'installation d'appareils électroniques dans les véhicules.

15. L'appareil ne doit pas être installé dans le poste de conduite d'un véhicule.

16. L'appareil doit être monté conformément aux pratiques acceptées du marché secondaire et aux matériaux d'installation du véhicule.

17. Utilisez uniquement des connecteurs homologués UL pour l'alimentation et la série.

18. L'entretien et la réparation de l'appareil doivent être effectués par un personnel qualifié. Cela inclut, mais sans s'y limiter, le remplacement de la batterie CMOS. La batterie CMOS de remplacement doit être du même type que celle d'origine.

19. L'élimination appropriée de la batterie CMOS doit être conforme à la gouvernance locale.

AVERTISSEMENT: Il existe un risque d'explosion si la pile CMOS n'est pas remplacée correctement. L'élimination de la batterie dans le feu ou dans un four chaud, ou l'écrasement ou le découpage mécanique d'une batterie peut entraîner une explosion.

7.6- Appendix F: CAD Files

7.7- Appendix G: Technical Resources

For technical resources, see Raspberry Pi Technical Support

7.8- Appendix H: NWK300 Spec sheet

For the NWK300 module, see NWK300

8- Security Advisory

For the latest security advisories concerning OnLogic products, including vulnerability disclosures and necessary updates, please refer to our official Security Advisories page. It is recommended to regularly check this resource for critical security information. Access Security Advisories