_ FCO RA81X-I013, Adhesive on gaskets & air filter break down ----------------------------------------------------------------------------| | _ _ _ _ _ _ _ | | | | | | | | | | Level of Page 1 | | |d|i|g|i|t|a|l| Urgency Of 27 | | |_|_|_|_|_|_|_| FCO [ I ] | |___________________________________________________________________________| | FIELD CHANGE ORDER Number: RA81X-I013 | |___________________________________________________________________________| | Applicability: | | If your HDA is marked "H1" or above, or has a serial number of | | CX 49250 or KB 6539 or above, THAT HDA IS GOOD AND DOES NOT NEED REPLACE- | | MENT. RA81 HDA's which are Revisions below "H1", or have serial numbers | | below CX 49250 or KB 6539, are subject to this FCO. For exceptions to | | this rule, see Page 3. | | | | | This revised FCO supersedes Revision B dated 05 June 1986. It has been| | | | revised to reflect changes in the Quick Check statement, the Bill of | | | Materials in EQ Kit: EQ-01380-01, and the rework procedure of | | | RA81X-I014. | |___________________________________________________________________________| | Problem/Symptoms: | | The adhesive used to attach the gaskets to the spindle air | | filter assembly breaks down at the upper end of the drive operating | | specification. This causes head to disk interference to occur. | |___________________________________________________________________________| | Quick Check: | | HDA Rev "H1" or S/N above CX 49250 or KB 6539 will have the | | adhesive removed from the air filter assembly and be a "GOOD" HDA. | |___________________________________________________________________________| | Compatibility/Prerequisite FCO: RA81X-R009, | Est. Time to Install | | RA81X-R012 and RA81X-I014 | 2.5/4.0 Hours | |___________________________________________________|_______________________| | Special Tools or Test Equipment: | | Velostat Kit P/N 29-11762-00 | |___________________________________________________________________________| | FCO Parts Information | |___________________________________________________________________________| | Order by | Contents | | FCO Kit # |____________________________________________________________| | | Quantity Part Number Description | | | | | EQ-01373-01 | 1 70-18491-01 See Page 3 | | EQ-01373-02 | 1 70-18491-02 See Page 3 | | FA-04656-01 | 1 FCO Document | | | | |______________|____________________________________________________________| | EQ Kit Variation/System-Option Applic: See Page 3 | |___________________________________________________________________________| | Approvals | |___________________________________________________________________________| | CSSE Engineer |F.S. Product Safety | F.S. Logistics | | Keith Brown | Steve Caccia | Ed Duggan | |________________________|_________________________|________________________| | Responsible CSSE Mgr |F.S. Microfiche Libraries| Affected Population | | Mike Mayfield | | 35,000 | |________________________| EP-FSP11-LB PDP11 |_______________________ | | ESD&P Micropublishing | EP-FSLCG-LB LCG | Initial Kitting | | Ray LeBlanc | EP-FSNVX-LB VAX | 28,000/7,000 | |________________________| |_______________________ | | Revision | VAXnotes | Hardcopy Publication | | C | STARS | 35,000 | |________________________| |________________________| | FCO Release Date | | Parts Availability | | 02 October 1986 | | December 1985 | +---------------------------------------------------------------------------+ _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 2 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ READING RA81 HDA SERIAL NUMBERS There have been problem reports from the Field in relation to locating the HDA serial number in preparation for the RA81 HDA FCO Program. The serial number for all RA series HDA's is on a sticker located on the top left hand section of the HDA housing. There are several different label types, and the serial number may have one of a group of different headers. Here is how to decode them. Only those numbers located on the sticker on the top left hand side of the HDA will reflect the true HDA serial number. Some HDA serial numbers will begin with a CX or KB prefix, and others with a R8* prefix. Some older HDA's will have serial number stickers that begin with a CX or KB on the label (e.g. CX 24876 or KB 05768). If this is the case, then you have the whole serial number right there. Newer HDA's have serial number stickers that contain a BAR CODE. For those HDA's with the BAR CODE type label, the numbers located directly under the Bar Code are to be used as the numeric part of the HDA serial number. e.g. If the number directly below the BAR CODE IS "*R81-063457*", then 63457 is the numeric part of the serial number. To determine the "ALPHA" portion of the serial number, which indicates where the HDA was built, look at the portion of the HDA label which states " S/N CX A B C D E F ". The two letters immediately following "S/N" are the "ALPHA" part of the serial number. The "ALPHA" portion will read either "CX" or "KB" for HDA's built in Colorado or Kaufbeuren respectively. In this example, the serial number would therefore be "CX 63457 ". The REVISION level of the HDA is shown on a sticker located next to (around the corner from ) the upper left hand corner of the rectangular plastic bulkhead cover on the front of the HDA. This label will contain the HDA part number and REVISION level. THE COMBINATION OF THE REVISION LEVEL AND SERIAL NUMBER IS THE ONLY WAY TO POSITIVELY IDENTIFY HDAS WHICH ARE CANDIDATES FOR THE UPCOMING FCO !!!!!! If your HDA is marked "H1" or above, or has a serial number of CX 49250 or above, or KB 6539 or above, THAT HDA IS GOOD AND DOES NOT NEED REPLACEMENT VIA THIS FCO. RA81 HDAs which are at Revisions below "H1" or which have serial numbers below CX 49250 or KB 6539 are subject to this FCO. There are only two exceptions to this rule. There are 3141 HDAs between serial numbers CX 49250 and 52390 which are free of the adhesive defect, but which were not marked "H1". They were marked "F1". These HDAs are NOT subject to the FCO. There are 1161 HDAs between serial numbers KB 6539 and 7700 which are free from the adhesive defect, but are marked "E1". These HDA's are NOT subject to the FCO either. Please note that as HDA's are repaired and the adhesive defect removed, the REVISION of the HDA is bumped to the most current REVISION LEVEL, at least "H1" presently. The serial number NEVER CHANGES!! Therefore it is possible to have a serial number like CX 2000 which is REVISION LEVEL "H1", and therefore a GOOD HDA!! _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 3 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ APPLICABILITY (cont.): There are only two exceptions to this rule. There are 3141 HDAs between serial numbers CX 49250 and 52390 which are free of the adhesive defect, but which were not marked "H1". They were marked "F1". These HDAs are NOT subject to the FCO. There are 1161 HDAs between serial numbers KB 6539 and 7700 which are free from the adhesive defect, but are marked "E1". These HDAs are NOT subject to the FCO either. ******************************************************************************* * N O T E * * Please note that as HDAs are repaired and the adhesive defect removed, * * the Rev of the HDA is bumped to the most current Rev, at least "H1" * * presently. The serial number NEVER CHANGES!! Therefore it is * * possible to have a serial number like CX 2000 which is Rev "H1", and * * therefore a GOOD HDA!! * * * ******************************************************************************* FCO Parts Information Order by Quantity: Part Number: Description: FCO Kit#: EQ-01373-01 1 70-18491-01 16 BIT RA81 HEAD DISK ASSEMBLY - OR - EQ-01373-02 1 70-18491-02 18 BIT RA81 HEAD DISK ASSEMBLY FA-04656-01 1 RA81X-I-013 FCO DOCUMENTATION **** WHEN YOU ORDER EITHER OF THE ABOVE KITS, YOU WILL RECEIVE ALL OF THE FOLLOWING KITS/PARTS/DOCUMENTATION *** EQ-01275-01 1 10-13466-22 0.1 MFD 50V CAPACITOR 1 13-05121-00 38.3 OHM RESISTOR,1/4 WATT, 1% EQ-01380-01 1 12-25629-01 GROUNDING STRAP 1 12-26091-01 CLIP, GROUNDING 1 90-10075-01 SCREW, TAP HEXWW 1 90-06565-00 NUT,HEX EXT TOOTH LCKWSHR 10-32 1 90-07651-00 WASHER, LOCK FA-04544-01 1 RA81X-R-009 FCO DOCUMENTATION FA-04649-01 1 RA81X-R-012 FCO DOCUMENTATION FA-04662-01 1 RA81X-I-014 FCO DOCUMENTATION PLEASE NOTE - IF YOU ORDER EQ-01373-01/O2, YOU WILL RECEIVE ALL THE OTHER EQ KITS LISTED ABOVE. IF YOU SHOULD NEED ADDITIONAL KITS, THEY WILL NEED TO BE ORDERED SEPARATELY. HDA REPLACEMENT FCO ************************************************************** * *** NOTE *** * * HDA'S SHOULD BE HANDLED WITH CARE AT ALL TIMES. DAMAGE * * WILL OCCUR FROM IMPROPER HANDLING. RETURNED HDA'S WILL * * BE REFURBISHED AND REISSUED FOR FIELD REPAIRS. * ************************************************************** _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 4 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ **************************************************************** * N O T E * * * * A period of time should be allowed for temperature * * stabilization to occur when transporting HDA's from colder * * to warmer environments, or vice versa. The possibility for * * condensation to form when the HDA has been cooled then * * heated quickly, is quite high. This causes head disk * * interference (HDI) to occur. The LED codes that can be * * expected are as follows: * * * * SERVO HEAD/MEDIA * * 25 4B 4D F8 F9 51 52 53 62 63 65 66 * * * * Arrangements should be made with the customer to insure * * that the HDA has time to stabilize. There is a requirement * * for a period of thermal stabilization of HDAs before they * * are spun up in drives. During the winter months, when a * * large portion of this FCO activity will take place in the * * Northern Hemisphere, the difference in temperature between * * an HDA that has just come in from being transported in the * * cold and a computer room environment can be quite large. * * If no time is allotted for this temperature difference to * * equalize, humidity in the air inside the HDA can actually * * condense into water inside the HDA and the probability of a * * head crash is high. The time required for stabilization * * varies directly with the difference in temperatures. * * * * In storage or shipping, (with the HDA packaged for shipping) * * the HDA should not be subjected to temperatures outside the * * range specified by DEC Standard 102, -40C (-40F) to 66C * * (151F). The maximum temperature gradient must not exceed 22 * * deg C per hour, or 40 deg F per hour. If the ambient * * temperature in which the HDA was stored was between 10C and * * 38C (50F and 100F), the HDA may be installed immediately. * * If the ambient temperature was between 0 deg C and 10C, * * (30F and 49F) the HDA should be allowed to warm to room * * temperature 22C, (appox. 70F) in the closed shipping * * container for three hours minimum and then installed. For * * temperatures below 0 deg C, (30F), allow 1 1/2 hours more * * for every 12 C (10 deg F) in addition to the three hour * * minimum. * * * * A very cold HDA that was stored in a van overnight at -23 C, * * (-10 deg F) for example, could take as much as 9 hours to * * thermally stabilize to the point where actual operation * * would not be risky. A maximum period of 13.5 hours could be * * required to allow thermal stabilization to take place from * * the lowest acceptable temperature to a standard computer * * room temperature. * * * * With this in mind, it may be appropriate to have HDAs * * delivered to the site which is to be FCO'ed the day or the * * evening before the acutal FCO installation is to take place. * * * **************************************************************** _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 5 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ **************************************************************** * HDA HANDLING INFORMATION * * * * A LARGE NUMBER OF THE HDA'S THAT ARE RETURNED FROM THE FIELD * * HAVE PROBLEMS THAT CAN BE AVOIDED IF THE FOLLOWING RULES ARE * * OBSERVED: * * * * 1) WHEN INSTALLING/DE-INSTALLING HDA'S THE HEADS/POSITIONER * * SHOULD ALWAYS BE IN THE "LOCKED" POSITION. * * 2) THE HEAD/POSITIONER SHOULD ALWAYS BE LOCKED PRIOR TO THE * * DRIVE BEING MOVED. * * 3) THE HDA SPINDLE/PULLEY SHAFT SHOULD NEVER BE SPUN BY * * HAND IN EITHER DIRECTION. * * 4) THE RUBBER SPINDLE/PULLEY SHAFT LOCK SHOULD BE INSTALLED * * WHEN RETURNING HDA'S FOR REPAIR. THIS LOCK IS BEING * * SHIPPED WITH ALL FIELD REPLACEMENT HDA'S. * * 5) WHEN REMOVING HDA'S FROM THE DRIVE, THE HDA SHOULD * * ALWAYS BE PLACED UPRIGHT ON THE PLASTIC BULKHEAD FEET * * END. IT SHOULD NEVER BE PLACED ON THE SPINDLE/PULLEY * * SHAFT. * * 6) WHEN CLOSING THE LOGIC CHASSIS ASSEMBLY THE HDA/DRIVE * * SHOULD BE SPUN DOWN PRIOR TO CLOSING. WHEN THIS CHASSIS * * DOES NOT CLOSE PROPERLY, THE LATCH SHOULD BE ADJUSTED. * * THE CHASSIS SHOULD NOT NEED TO BE SLAMMED SHUT. * * 7) WHEN INSTALLING THE DRIVE, ALL HDA SHIPPING BRACKETS * * SHOULD BE REMOVED, AND HDA HOLD DOWN NUTS SHOULD BE * * REPLACED. THESE NUTS SHOULD BE VERY FIRMLY TIGHTENED * * BUT ONLY FINGER TIGHT. DO NOT OVER TIGHTEN THE NUTS, * * THIS WILL CAUSE THE SHOCK MOUNTS TO BECOME INEFFECTIVE. * * 8) ESD PROTECTION SHOULD ALWAYS BE OBSERVED WHEN HANDLING * * HDA'S. * * 9) ALWAYS USE THE RUN/STOP SWITCH TO SPIN THE DRIVE DOWN. * * !!NEVER!! USE THE DRIVE CIRCUIT BREAKER TO STOP THE * * DRIVE. * * 10) ALWAYS USE THE HDA SHIPPING CONTAINER FOR TRANSPORTATION * * OF HDA'S TO AND FROM THE SITE. IT IS DESIGNED TO * * PROTECT THE HDA FROM BEING DAMAGED DUE TO MISHANDLING. * * HDA'S SHOULD REMAIN IN THE BOX UNTIL REMOVED FOR THEIR * * ACTUAL INSTALLATION INTO THE DRIVE. !!NEVER!! TRANSPORT * * AN HDA ON ANY KIND OF WHEELED CART WITHOUT THE HDA BEING * * IN ITS BOX !!! * **************************************************************** ************************************************************** * *** NOTE *** * * * * THE PREREQUISITE TO THIS FCO IS THE INSTALLATION OF FCO'S * * RA81X-R-009, RA81X-R-0012 AND RA81X-I-014 (SEE FCO QUICK * * CHECK'S BELOW). IF THESE FCO'S ARE NOT ALREADY INSTALLED, * * IT IS RECOMMENDED THAT THEY BE INSTALLED BEFORE INSTALLING * * A NEW HDA. * ************************************************************** _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 6 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ ------------------------------- | QUICK CHECK FOR RA81X-R-009 | ------------------------------- (SEE ATTACHED RA81X-R-009 FOR COMPLETE FCO OVERVIEW AND INSTRUCTIONS). PRESENCE OF 0.1 UFD CAPACITOR AT LOCATION C29 AND 38.3 OHM PRECISION RESISTOR (ORANGE-GRAY-ORANGE) AT LOCATION R64. RA81X-S-004, R/W MODULE (54-15253) MUST BE AT CS REVISION LEVEL "D" BEFORE INSTALLATION OF THIS FCO. PROBLEM - HIGH RATE OF ERROR CODES 62 AND/OR 63. INTERMITTENT, UNEXPLAINED BURSTS OF ECC ERRORS. ------------------------------- | QUICK CHECK FOR RA81X-R-012 | ------------------------------- (SEE ATTACHED RA81X-R-012 FOR COMPLETE FCO OVERVIEW AND INSTRUCTIONS) MICROPROCESSOR DATA SEPARATOR WINDOW ADJUSTMENT THE JUMPERS ARE LOCATED BETWEEN E169 AND E170 NEXT TO J304 READ/WRITE CABLE CONNECTOR. READ/WRITE CABLE -----------------------------------------------|---------------------- | |----| |----| |--------------------| | E | | | | | E | | J304 | | | W W W | | | | | 1 | 9 7 8 | 1 | ---------------------- | 6 | | | | | 7 | | 9 | | | | | 0 | | | | | | | | ------ ------ !!!THE FOLLOWING SETTINGS ARE THE ONLY ADJUSTMENTS THAT CAN BE MADE.!!!! IF ANY OTHER ADJUSTMENTS ARE PERFORMED THE DATA SEPARATOR WINDOW WILL BE OUT OF TOLERANCE.!!! OLD SETTING CHANGE RESULT ----------- ------ ------ W9,W8,W7 OUT ADD W9 W9 IN W9 IN W7,W8 OUT ADD W8 W8 W9 IN W8 IN W7,W9 ADD W7 AND W9 REMOVE W8 W7 W9 IN W9 AND W8 IN W7 OUT ADD W7 REMOVE W8 W7 W9 IN ******************************************************************************* * MICROPROCESSOR MODULES WITH AN ETCH "B", C.S. "K1" OR ETCH "C1",C.S. "M1" * * REVISIONS SHOULD NOT BE ADJUSTED. RA81'S AT HARDWARE REVISION 6 WILL HAVE * * THE "M1" OR THE "H2" MICROPROCESSOR. * ******************************************************************************* ------------------------------- | QUICK CHECK FOR RA81X-I-014 | ------------------------------- (SEE FCO RA81X-I-014 FOR COMPLETE FCO OVERVIEW AND INSTRUCTIONS). HDA CHASSIS AND DRIVE CHASSIS ARE AT DIFFERENT GROUND REFERENCE. DATA ERRORS (ECC) AND OTHER MISC. ERRORS NOT RELATED TO MEDIA DEFECTS. _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 7 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ HDA REMOVAL PROCEDURE --------------------- 1. Request the RA81 drive from the customer. ******************************************************* * A COMPLETE BACKUP MUST BE PERFORMED BEFORE STARTING * * THIS PROCESS. A LOG AND VERIFY OPERATION SHOULD BE * * USED DURING THE BACKUP/RESTORE PROCESS. * ******************************************************* ------------------------------------------------------------------------ | RA81 VAXCLUSTER BACKUP NOTES | | ---------------------------- | | Before replacing an RA81 HDA, proper media backup MUST be done, | | preferably by the site system manager. CX-CSSE recommends using the | | VMS Backup utility for maximum data integrity. | | | | Although the VMS Backup utility and procedures (to tape) are | | considerably slower than the HSC50 BACKUP and RESTORE utilities, | | potentially fewer tapes are used in VMS Backups, and write | | verifications are done if the /VERIFY qualifier is used with the VMS | | BACKUP command. | | | | When invoking the VMS BACKUP utility, be sure that your customer uses| | the /REWIND and /VERIFY qualifiers to assure data integrity. BACKUP | | generated tape volume headers may become corrupted and render the | | remainder of the data on that tape volume inaccessible if those 2 | | qualifiers are not used. This is due to a VMS V4.0, VMS V4.1 and | | VMS V4.2 tape class driver bug. | | | | The recommended command string for VMS Backup is: | | | | $Backup/Image/Verify/Rewind 'source_disk:' 'target_device:' | | | | The Backup utility should be run from a hardcopy terminal, and all | | output messages from this backup should be preserved and reviewed by | | the field engineer installing the RA81 HDA FCO and the site system | | manager. Any abnormal BACKUP messages ie. %BACKUP-E-BADDATA OR | | -FORCEDERROR should be flagged and any questions regarding the | | messages and recovery actions should be routed by the field service | | engineer to the respective support groups OR TSC. | | | | For optimum speed, an HSC50 Backup will utilize (4) 2400 ft. reels of| | tape to completely backup an entire RA81 drive. The HSC50 BACKUP | | utility does a physical backup of a RA series disk and has no | | knowledge of any type of operating system file structures on a disk. | | The HSC50 Backup utility uses the tape functionality of read after | | write, but does not do complete rewind and read verification. | | | ------------------------------------------------------------------------ _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 8 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ ------------------------------------------------------------------------ | ULTRIX BACKUP NOTES | | ------------------- | | The best possible way to back up the file systems on RA81's is to do | | a zero level dump of each file system on the RA81. | | | | THIS SHOULD BE DONE AT THE SINGLE USER LEVEL. | | | | There is no verify pass under the dump program. Due to tape errors it| | maybe wise to dump each file system tape twice...But that should be | | up to the customer. After the HDA is replaced the customer will have | | to make new file systems on the RA81. Details of the "backup" | | process are available in the software notebooks. | | | | Additional information, or specific instructions, can be provided by | | the ULTRIX Customer Support personnel at the Customer Support Center.| | RSTS/E BACKUP NOTES | | ------------------- | | For the customer that has multiple RA81's, using the SAVRES program | | to do an IMAGE copy from one RA81 to another would be the fastest and| | most effective method. If only using a Mag Tape drive in the backup, | | SAVRES can be used also. Doing an image SAVE to "tape" can be | | accomplished, however, in all cases the /VERIFY switch should be used| | and possibly a second SAVSET for safety sake. | | | | RSTS development feels that SAVRES is easiest, especially for V7.2 | | and V8.0. They also suggest that 2 backups are better than one. | | | | When possible a BACKUP of the customer data should ALSO be done. V7.2| | and V8.0 use the "old" RSTS backup. V9.0's new backup is easier and | | more reliable than the "old". This backup can be used to selectively | | restore customer files should the need arise. Save sets cannot be | | restored selectively. | | | | Since the "new" version 9.X backup is not widely known, the customer | | should reference the software documentation (if its not familiar). | | | | SAVRES also has the ability to "halt" on the occurrence of an error | | during the "copy" of the data. If you wish to have SAVRES halt on the| | occurrence of an error, the /NOERROR switch can also be used. This | | way any error can be examined on its occurrence and the "backup" | | terminate. The error may have to be "repaired" before restarting the| | SAVRES "backup". | | | | It would also be recommended that customers, "clean-out" any files | | that are no longer needed, before starting the SAVRES. This way any | | files that will no longer be needed, can be deleted and not add to | | the time that SAVRES runs. | | | | Details of the SAVRES, and BACKUP, commands are in the RSTS/E System | | Managers Guide. Any additional information needed or help in the | | process can be directed to the customers local DEC Software Support | | Specialist, or if necessary the Customer Support Center RSTS/E | | Customer Support Personnel. | | | |----------------------------------------------------------------------| _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 9 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ |----------------------------------------------------------------------| | | | | | RSX11M (+) BACKUP NOTES | | ----------------------- | | | | | | DISK TO TAPE | | ------------ | | | | We recommend using online BRU (M-PLUS V2.1 Update E or later/11M V4.1| | update E or later) if that is possible. If it is not possible, | | because the disk to be backed up is the system disk, (i.e. the disk | | that the system was booted from), standalone BRU (BRUSYS or BRU64K) | | from the M-PLUS V3.0/11M V4.2 distribution should be used instead. | | | | UNDER NO CIRCUMSTANCES SHOULD BRU /IMAGE (FROM ANY DISTRIBUTION) BE | | USED!!!! | | | | The recommended procedure for backing up and restoring an entire disk| | to tape is: | | | | | | 1) For online BRU | | >MOU mmn:/FOR ; mount the tape foreign | | >MOU ddn:/FOR ; mount the disk foreign (to insure exclusive| | ; access) | | >BRU /VER ddn: mmn: ; backup with verify (each tape will be | | ; verified immediately after it is written) | | | | | | After the HDA is replaced: | | >BAD ddn: ; run BAD on the NEW disk | | >BRU /VER/INI mmn: ddn: ; restore with verify (the entire disk | | ; will be restored before the verify | | ; pass) | ------------------------------------------------------------------------ _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 10 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ |----------------------------------------------------------------------| | CONTINUED RSX11M (+) BACKUP NOTES | | | | 2) For standalone BRU, boot up BRU64K (on 11M) or BRUSYS (on M-PLUS),| | then you will be prompted for the devices you are going to use | | (see p. 7-23 of the "Utilities Manual"). You can enter /DEV at | | this point to see if the vectors and CSR's are correct for the | | devices you wish to use (they are correct if the device shows | | online, they are incorrect if the device says offline). You can | | enter the correct vector and CSR at this point - the example below| | shows this. | | | | Enter first device: DU0:/CSR=172150/VEC=154 | | Enter second device: mmn: | | >RUN BRU | | BRU>/VER ddn: mmn: ; backup with verify (each tape will be | | ; verified immediately after it is written) | | After the disk is replaced, you will have to reboot BRU as before,| | and answer the device questions as before. Then | | | | >RUN BAD ; run BAD on the new disk | | BAD>ddn: | | >RUN BRU | | BRU>/VER mmn: ddn: ; restore with verify (the entire disk will | | ; be restored before the verify pass) | | | | Note: Backing up a "full" RA81 to tape at 1600 BPI may require | | between 13 and 15 2400 ft. tapes. For the purpose of HDA | | replacement, the tapes used should be the best quality you can | | find (AT LEAST certified to 6250 BPI) | | | | NOTE | | 11M V4.2 and M+ V3.0 have not yet gone to the SDC. So for | | those systems where they must use standalone BRU, A copy | | of standalone BRU will need to be obtained. | | (if it hasn't shipped by then, or if the customer is not under | | contract). | | | | If the customer isn't running a recent version of RSX, | | It will be difficult to advise what to do. | |----------------------------------------------------------------------| _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 11 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ |----------------------------------------------------------------------| | | | DISK TO DISK COPIES | | ------------------- | | - If the customer has a tape drive - use the tape method | | - If they have another RA81, they can use the same | | method we recommend for tape - just substitute the second disk | | name for the tape unit | | - If they have other disks that are big enough to hold the data from | | the RA81 assuming it's not full, they can use BRU to copy the | | data to that other disk - | | - The biggest problem with disk to disk copies, is that | | the /IMAGE mode of BRU which is used to copy a big disk to | | multiple little disks in BRU format doesn't always work - and | | you don't know it didn't until you try to restore - a problem we| | definitely want to avoid. | | | | | | DSM-11 (MUMPS) BACKUP NOTES | | --------------------------- | | | | The DSM-11 BACKUP utility is the best way to go. DSM-11's BACKUP | | utility DOES NOT have a verify option! | | | | It might be wise to do the BACKUP and then do a RESTORE to make sure | | the BACKUP worked. In this case the BACKUP would have to be done to | | some other media or a "scratch" RA81, in order to preserve the | | "master" copy being backed-up, until it can be "verified" that the | | backup copy is good. | | | | DSM-11 just finished field test, so a new release, V3.1 may well be | | in the field by the time you start doing any of this. I will mention | | that 3.0A BACKUP had problems and BACKUP has been rewritten for the | | new release. | | | | Specific instructions for the use of the BACKUP utility is in the | | software manuals. Any additional information on the use of this | | utility can be directed to the appropriate DSM-11 Customer Support | | Personnel. | | | | IAS BACKUP NOTES | | ---------------- | | Since IAS is a "type" of RSX, many of the RSX concepts need to be | | understood. IAS has a backup utility like the RSX "BRU" that can be | | used. | | | | IAS engineering has suggested that the best way to go is to use | | BRU with verify enabled. Then re-run BRU with the compare | | qualifier. | | | ----------------------------------------------------------------------- _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 12 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ ------------------------------------------------------------------------ | TOPS-20 | | ------- | | | | The best way to proceed is as follows: | | | | 1) Run the DLUSER utility to preserve ALL the directory information | | on a structure. The file containing this information should | | probably be put in a secure environment such as rather | | than . Also, the DLUSER data should be kept in machine | | readable form and (as silly as it sounds) make sure the DLUSER | | data does NOT go on the HDA or structure about to be replaced. | | 2) Use DUMPER to do a FULL save of the entire structure. One should | | probably do this on a 6250 BPI Tape drive (@6250 BPI) at some | | relatively high blocking factor such as 8 or 10. TU72s or TU78s | | are probably the best way to do this. | | 3) REWIND the DUMPER tape. | | 4) Run the CHECK DUMPER function to verify the data that you've | | backed up. | | | | Obviously, there should be no users of the structure at the time of | | the full save. Also, it might be a good idea to run the tape drive | | reliability diagnostic to be on the safe side. | | | | | | Once the FCO is complete: | | ------------------------- | | 1) Run CHECKD to rebuild the structure. | | 2) Use DLUSER to replace all the directories on the structure | | 3) Then do a full restore on the structure using the DUMPER tapes you| | earlier produced/verified. | | | | The DLUSER steps are probably critical because DUMPER does not | | preserve all directory attributes in some versions in the field. | | | | This is all covered in one of the following three places - the | | OPERATOR's guide (vol. 10 of the SW notebooks), the System Manager's | | Guide (vol. 9) and the KL Model B Installation guide (also vol 9). | | | | You should also be aware that a structure under TOPS-20 can span up | | to 4 RA81 spindles. This means that once one spindle/pack is | | replaced, the ENTIRE structure must be rebuilt. Said another way, | | to replace one HDA, the entire volume-set must be backed up and | | reconstructed. | | | | Tight cooperation between the engineer replacing the HDA and the | | systems programmer/manager is encouraged. | |______________________________________________________________________| _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 13 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ - CONTINUATION OF FCO PROCESS - 2. The RA81 drive must be dismounted and deselected. 3. Depress the "A and B" port switches on the Operator Control Panel to the "OUT" position. (Figure 1) 4. Spin the drive down by pressing the RUN/STOP switch. (Figure 1) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 14 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 5. Open the back door of the cabinet. ****************************************************** * C A U T I O N * * * * Before procedding, turn off the AC Circuit Breaker * * at the rear of the Drive and disconnect the main * * AC power cord from the power supply on the rear of * * the Drive. (Figure 2) * ****************************************************** 6. If this is a fixed mount drive, proceed to step 11. _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 15 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 7. Pull out the cabinet stabilizer bar. (Figure 3) ****************************************************** * C A U T I O N * * * * Never slide a drive out of the cabinet without * * extending the cabinet stabilizer bar. * * * ****************************************************** _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 16 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 8. Remove the screw holding the back of the disk drive to the electrostatic discharge bracket. (Figure 4) 9. Slowly pull the Drive out, until the slides lock into place. _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 17 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 10. Push up on the slide lock arm "A" to extend the Drive all the way out. (Figure 5) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 18 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 11. Depress the logic chassis release latch with a standard screwdriver and raise the chassis. (Figure 6) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 19 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 12. Attach E.S.D. wrist strap to chassis ground stud. (Figure 7) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 20 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 13. Disconnect cables P501 and P502 from the Read/Write module. (Figure 8) 14. Disconnect cables P601, P602 and P603 from the HDA bulkhead cover. (Figure 8) 15. Remove the Read/Write module from the HDA by removing the four (4) hold down screws. 16. Place the positioner/head locking arm in the locked position. (Figure 8) 17. Remove the four (4) HDA retaining nuts from the shock mounts. (Figure 8) 18. Place the belt tension lever in the released position. (Figure 8) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 21 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 19. Gently lift the HDA assembly out of the lower chassis and place it on a flat work surface. HDA's should always be placed on the work surface with the plastic bulkhead feet facing down. (Figure 9) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 22 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ HDA INSTALLATION PROCEDURE -------------------------- 1. Remove the new HDA from the shipping container and place it gently on a flat work surface. HDA's should always be placed on the work surface with the plastic bulkhead feet facing down. (Figure 9) 2. Remove the plastic spindle/pulley lock from the spindle shaft of the new HDA. (Figure 10) 3. Attach the spindle/pulley lock to the old HDA spindle shaft. (Figure 10) _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 23 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 4. Install the new HDA into the lower chassis. 5. Reattach the four (4) HDA hold down nuts to the shock mounts. The nuts should be quite firm and snug, but only be FINGER TIGHTENED. (Figure 8) *************************************************************** * NOTE * * * * THE INSTALLATION OF FCO RA81X-I-014 SHOULD BE PERFORMED AT * * THIS TIME. ALSO VERIFY THAT FCO RA81X-R-009 HAS BEEN * * INSTALLED. IF IT IS NOT INSTALLED, DO SO AT THIS TIME. * *************************************************************** 6. Once FCO RA81X-R-009 and RA81X-I-014 have been completed, then reattach the Read/Write module using the four (4) hold down screws. 7. Reconnect cables P501, and P502 to the Read/Write module. (Figure 8) 8. Reconnect cables P601, P602 and P603 to the bulkhead cover. (Figure 8) 9. Place the belt tension lever in the engaged position. (Figure 8) 10. Place the positioner lock arm in the unlocked position and remove the E.S.D. wrist strap from the ground stud. (Figure 8) 11. Close, but DO NOT SLAM the logic chassis. ----------------------------------------------------------------- | NOTE | | | | AT THIS TIME, VERIFY THAT THE INSTALLATION OF FCO RA81X-R-012 | | HAS BEEN PERFORMED. IF NOT INSTALLED, PERFORM THIS FCO AT | | THIS TIME. | ----------------------------------------------------------------- _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 24 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 12. If this is a fixed mount drive, proceed to step 15. 13. Push in on slide arm "B" and slowly slide the Drive back into the cabinet. (Figure 5) 14. Reinstall the screw holding the back of the Drive to the electrostatic discharge bracket. (Figure 4) ******************************************************* * C A U T I O N * * * * The screw holding the back of the Drive to the * * electrostatic discharge bracket must be installed. * * * ******************************************************* 15. Reconnect the AC power cord, at the rear of drive, to the AC receptacle. (Figure 2) 16. Turn the AC Circuit Breaker, at the rear of the drive, to the "ON" position. (Figure 2) 17. Spin up the Drive by pressing the RUN/STOP switch. (Figure 1) 18. After the Drive has spun up and a ready light is "ON", press the "A" and/or "B" port switches on the Operator Control Panel to the "IN" position. (Figure 1) 19. Run the appropriate RA81 drive diagnostics for at least 30 minutes. VAX 32 BIT UDA50, EVRLA or EVRLG HSC50/ILEXER PDP-11 16 BIT UDA50, CZUDC or CZUDI DEC 10/20 36 BIT HSC50/ILEXER 20. Return the RA81 drive to the customer for software restore/initialization. 21. Enter all FCO activity in the Site Management Guide. 22. Complete the LARS form as shown in APPENDIX A. 23. Lock the Head/Positioner and reinstall the spindle locking strap onto the old HDA (Figure 10). Fill out the attached form (Appendix B) and carefully place the old HDA, along with this form, in the shipping container and return it to your Logistics Department. _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 25 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 26 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ _ _ _ _ _ _ _ | FCO RA81X-I-013 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 27 OF 27 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ \^ RA81X \\RA81X \\RA81X-I013 \\BROWN \\1986 \\OCT \\FCO_DOCS