_ FCO KA86-M008, Removed/Discarded Green Bonding Wire (Mandatory) +-----------------------------------------------------------------------------+ | | | _ _ _ _ _ _ _ Level of Urgency Page_1_ | || | | | | | | | +--+ Of_19_ | ||d|i|g|i|t|a|l| PRELIMINARY FCO |M | | ||_|_|_|_|_|_|_| +--+ | |_____________________________________________________________________________| | | | FIELD CHANGE ORDER Number: KA86-M008 | |_____________________________________________________________________________| | Applicability: | | Retrofit all VAX 86XX systems with altered and/or removed bonding wires, | | in the Russellstoll receptacles. This FCO implements the means to correct | | any unauthorized changes to the Russellstoll receptacles. Refer to Page #3 | | Objective section, for more details. | |_____________________________________________________________________________| | Problem/Symptom: | | Green bonding wire connected to the casing of the Russellstoll Receptacles | | has been removed or disconnected. Refer to Page #4, Problem section. | |_____________________________________________________________________________| | Quick Check: | | Green bonding wire SHOULD BE attached to the casing of the receptacle | | or cordset. | |_____________________________________________________________________________| | Compatibility/Prerequisite FCO: N/A | Est. Time to Install: | | | 1.0 Cordset & .75 BC29A | |___________________________________________________|_________________________| | Special Tools or Test Equipment: | | Torque Wrench P/N 29-20906-00 and applicable Bit Set P/N 29-26193-00. | |_____________________________________________________________________________| | FCO Parts Information | |_____________________________________________________________________________| | Order by | Contents | | FCO Kit # |________________________________________________________| | | Quantity: Part Number: Description: | | EQ-01432-0X | 1 See Page #3, Logistics | | FA-04718-01 | 1 FCO Document | |_____________________________________________________________________________| |EQ Kit Variation System/Option Applic: Applies to ALL VAX 86XX systems | |_____________________________________________________________________________| | Approvals | |_____________________________________________________________________________| | CSSE Engineer | F.S. Product Safety | F.S. Logistics | | Terri Cygan | Jerry Gannelli | Ed Duggan | |____________________|__________________________|_____________________________| | CSSE Manager | F.S. Microfiche Libraries| Affected Population: | | Barry Sullivan | | 65 | |____________________| EP-FSNVX-LB VAX |____________________________ | | ESD&P Micropub. | | Initial Kitting: | | Ray LeBlanc | VAXnotes | 50/10/3/2 | |____________________| STARS |____________________________ | | Revision: | | Hardcopy Publication: | | A | | 100 | |____________________| |_____________________________| | FCO Release Date | | Parts Availability: | | September 86 | | November 1986 | +-----------------------------------------------------------------------------+ _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 2 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ DISCLAIMER: Digital Equipment Corporation has designed the KA86 and associated cabinets and peripherals to be Class I (IEC) Equipment which requires a Safety Earth Grounding Conductor (green and yellow wire) in the fixed wiring of the facility where it is installed. This Grounding Conductor (versus conduit) should be continuous all the way back to the building's Earth reference point. Certain electrical codes may allow conduit or similar conductive materials to be substituted in part, or in whole, for this Grounding Conductor. Digital Equipment Corporation expects a continuous Safety Earth Grounding Conductor with proper bonding at panel boxes and throughout it's distribution, to the computer equipment's power cord, and accepts no responsibility for loss of continuity of this Grounding Conductor between the computer equipment's power cord and Earth. Material Returns: For a non-contract customer the local Digital Field Branch will verify the validity of customer requests for this FCO. The Field Branch will coordinate the exchange (return) of non-conforming materials from the customer. This will assure control of the non-conforming material (and avoids billing). _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 3 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ LOGISTICS: (FCO Parts Information, Continued from Page 1) EQ Kit #: Qty: Part Number: Description: EQ-01432-01 1 12-19321-02 Russellstoll Receptacle, 60 amps EQ-01432-02 1 12-20523-01 Russellstoll Receptacle, 30 amps EQ-01432-03 1 70-19891-13 KA86 Cordset, 60 amps EQ-01432-04 1 70-19872-13 KA86 Cordset, 30 amps FA-04718-01 1 FCO Document ************************************************************************* * NOTE * * This FCO must NOT be attempted without Torque Wrench P/N 29-20906-00, * * and the applicable Bit Set P/N 29-26193-00 (or suitable alternatives).* ************************************************************************* Torque Wrench (P/N 29-20906-00), is a ratchet style torque wrench capable of 100 inch-pounds (for 60 amp connectors) and 20 inch-pounds (for 30 amp connectors). Bit Set (P/N 29-26193-00), contains a 5/32 inch hex bit (for 60 amp connectors) a 3/16 inch flat bit (for 30 amp connectors) and an adapter for the torque wrench (1/4 inch drive). OBJECTIVE: This is a Mandatory (safety) FCO because a risk of personal injury may result from a fault within the connector if its case is not tied to ground. There is no defect/problem with any Russellstoll connector UNLESS it has been altered on site. This FCO is a means to correct unauthorized alterations made to Russellstoll connectors. These alterations should NOT have taken place. Implementation is on an "As Needed" basis. ************************************************************************* * NOTE * * This FCO does not require an audit of all systems. This is * * intended for systems which are known or suspected of having had an * * un-authorized change/modification. * ************************************************************************* For ALL (Warranty, Contract and Per Call) customers, Digital will supply at NO cost, the labor and materials for the parts Digital supports, such as the BC29A cable. Digital will supply at no cost, materials ONLY for the products Digital DOES NOT support, such as the receptacle connected to the customer's electrical wiring. _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 4 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ PROBLEM: This FCO addresses specific installations where Russellstoll power connectors have been modified such that the Ground Bonding Jumper (green wire) between the Grounding Conductor (green/yellow wire) and the connector case has been REMOVED. EQ kits are available to correct any such modification, by replacing the connector's ground sleeve with one which includes a new Ground Bonding Jumper. Products affected are (female) sleeve type connectors: - Receptacle Series #6516 (60 amps) P/N 12-19321-02 - Receptacle Series #3401 (30 amps) P/N 12-20523-01 - Power Cable; using Receptacle Series #6516 (60 amps) P/N BC29A-XX ************************************************************************* * NOTE * * The KA86 power cords (P/N 70-19891-13 and P/N 70-19872-13), use the * * (male) pin type connectors and may also have been altered. This * * results in NO risk of personal injury PROVIDED the (female) sleeve * * connectors (addressed by this FCO) have their case properly grounded.* ************************************************************************* If, for compliance reasons, alteration of a power cord needs to be corrected, a new (70-class) part must be ordered and the entire power cord replaced. Reference Section 2, Power Down Procedure and Drawing #IC-7019218 (included). _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 5 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ KA86-M008 Rework for the Russellstoll Connectors ***************************************** * CAUTION * * * * These INSTRUCTIONS MUST BE FOLLOWED * * in sequence PRIOR to accessing * * ANY suspect power connector. * ***************************************** SECTION BREAKDOWN: Receptacle Replacement; Refer to Section #3 P/N 12-19321-02; 60 amps and P/N 12-20523-01; 30 amps ************************************************* * WARNING * * * * Installation of these parts MUST BE DONE * * by the Customer's Certified Electrican ONLY. * ************************************************* BC29A Connector; Refer to Section #4 Installation of these parts MAY be done by the Customer's Certified Electrican OR a Field Service Engineer. SECTION #1: System Integrity Testing ************************************************************************* * NOTE * * As a precaution, especially for Per Call customers, diagnostics * * should be run on the CPU Kernel and I/O Devices, prior to * * installation of this FCO. * ************************************************************************* _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 6 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 1. Execute the TSTCPU.COM file to verify system integrity This will test the complete CPU (taking about 45 minutes). >>>@TSTCPU 2. Execute MACRO cluster diagnostics. a. Load the Diagnostic Supervisor and set up the devices. >>>@EDSAA DS> ATT KA86 HUB KA0 Y Y 0 1 DS> SEL KA0 b. Run CPU MACRO Cluster diagnostics. DS> R diagnostic_name Diagnostics to be run are: EVKAB EVKAC EVKAD EVKAE EVKAM 3. For a VMS operating system; run one ERROR Free pass of the UETP System Exerciser. 4. For ULTRIX operating systems, run an ERROR Free pass of the SYSTEM EXERCISERS (applicable to your system) found in the /usr/field directory. The system exercisers are: cmx(8) tests terminal communications system dskx(8) tests disk drives fsx(8) tests the file systems lpx(8) tests the line printers memx(8) tests the memory mtx(8) tests the magnetic tape drives ************************************************* * NOTE * * Use online help (-h) for more information. * * Example: # dskx -h * ************************************************* _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 7 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ SECTION #2; Power Down Procedure 1. Power off the VAX86XX, by turning the SCP (System Control Panel) Terminal Control Switch, to the OFF position. 2. Open the front panel door and set the Main Circuit Breaker (CB1), of the 876-A Power Controller, to the OFF (0) position. 3. Observe the three pilot lamps on the 876-A which are mounted vertically and to right of CB1. All three lamps should be lit. ******************************************************** * NOTE * * If lamps are NOT lit, STOP and replace lamps with * * functional pilot lamps (P/N 12-19281-00). * ******************************************************** ************************************************************************* * WARNING * * DO NOT UTILIZE the 60/30 ampere CIRCUIT BREAKER at the rear of the * * Front End Cabinet. This Circuit Breaker MUST remain in the "ON" * * (1) position for the 876-A Pilot Lamps to be lit. * ************************************************************************* 4. Check with the Customer to locate the Disconnect Device, for the CPUs Main Power and disconnect the power. All three pilot lamps on the 876-A should go OFF. ************************************************************************* * WARNING * * If ANY pilot lamps are still lit, you HAVE NOT located the proper * * branch circuit disconnect. Do NOT proceed UNTIL the proper branch * * circuit disconnect device has been found and utilized causing all * * three pilot lamps to go OFF. * ************************************************************************* 5. Locate the Russellstoll plug at the end of the KA86 power cord and its mating receptacle. 6. Disconnect the power cord from its mating receptacle. SECTION #3; Inspection, Removal and Replacement Procedure for Russellstoll Receptacles; P/N 12-19321-02 (60amps) and P/N 12-20523-01 (30amps). Refer to Diagrams P/N 7019218-0-1, Revision A (attached, 4 pages), for further details. _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 8 OF 19 |_|_|_|_|_|_|_| | _______________________________|_________________________________________ If there is any reason to believe that the GREEN BONDING wire, in any of the noted Russellstoll receptacles or connectors, has been ALTERED in any way, AFTER following power down sequence, PERFORM the following inspections (where applicable): ********************************************************************** * NOTE * * Torque Wrench P/N 29-20906-00 and the applicable Bit Set P/N * * 29-26193-00 (or equivalent), MUST BE on hand BEFORE proceeding. * ********************************************************************** ************************************************************** * CAUTION * * To be PERFORMED by customer's Certified Electrician ONLY. * ************************************************************** 1. Ensure that the Power Down sequence (refer to Section #2) has been PROPERLY performed before proceeding. 2. Disconnect (4) mounting screws located on receptacle (and save). 3. Loosen the receptacle from its mount so that the center pin of the receptacle and the green bonding wire is visible. 4. If the GREEN bonding wire is ATTACHED to the CENTER PIN and to the CASING of the receptacle, leave as is and REPLACE the (4) mounting screws and go to POWER UP section. 5. If the GREEN bonding wire has been REMOVED/CUT, note the proper wiring and REMOVE the currently installed Russellstoll receptacle. 6. Install the NEW receptacle as previously wired. ********************************************************* * WARNING * * The GREEN bonding wire MUST stay ATTACHED to the * * casing of the receptacle, thus BONDING the case to * * the grounding conductor sleeve. * ********************************************************* *********************************************************************** * NOTE * * The torque wrench provided in P/N 29-20906-00 must be properly * * set and "cocked" prior to use. Read the instructions accompanying * * this tool thoroughly. Dial in the proper torque value. Holding * * the torque wrench with its bit drive facing away from you, assure * * the rachet lever is set to the left and that the entire rachet * * head is "cocked" to the right. The wrench is now ready for * * tightening the Russellstoll pressure screws to the proper torque. * * Once the racket head has clicked from its cocked position, proper * * torque has been reach. Continued force will damage the tool and/ * * or the pressure screws. * *********************************************************************** _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 9 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 7. Torque all pressure screws to manufacturer's specification; of 100 inch-pounds for 60 amp connector or 20 inch-pounds for 30 amp connector, paying special attention to the pressure screw of the grounding conductor sleeve. 8. Check insulation resistance to be sure NO shorts are present. 9. Perform POWER UP procedure (refer to Section #4, of this procedure). 10. REMOVED Receptacles MUST be RETURNED to the Digital office from which it was obtained, for proper control of non-conforming materials. SECTION #4; Inspection, Removal and Replacement Procedure for Grounding Pin and Jumper located in the BC29A Russellstoll Connectors. Refer to the attached Figures #1, #2 and #3, for further details. *********************************************************************** * NOTE * * Torque Wrench P/N 29-20906-00 and the applicable Bit Set P/N * * 29-26193-00 (or equivalent), MUST BE on hand BEFORE proceeding. * *********************************************************************** ************************************************** * CAUTION * * To be PERFORMED by Digital Field Engineer or * * customer's Certified Electrician. * ************************************************** 1. Ensure that the Power Down sequence (refer to Section #2) has been PROPERLY performed before proceeding. 2. Disconnect (3) mounting screws and (1) bolt w/chain attached located on receptacle part of the BC29A-xx cable and save. 3. Loosen the receptacle from its mount and pull the slack from the wires in the cable, so that the center pin of the receptacle and the green bonding wire are visible. 4. IF the GREEN bonding wire is ATTACHED to the CENTER pin and to the CASING of the Receptacle, LEAVE as is and REPLACE the (3) mounting screws and (1) bolt w/chain. Then go to Power Up section (refer to Section #5, of this procedure). 5. IF the GREEN bonding wire has been REMOVED, obtain the appropriate Russellstoll receptacle for replacement. EQ-01432-01 (P/N 12-19321-02; 60amp receptacle) EQ-01432-02 (P/N 12-20523-01; 30amp receptacle) _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 10 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ 6. Remove the center pin of the replacement receptacle, by removing the set screw with an allen wrench and disconnecting the green bonding wire from the casing, of the receptacle. 7. Remove the center pin of the altered receptacle and replace it with the new center pin and its attached green bonding wire. 8. After placing the center pin in the center slot of the receptacle, attach the green bonding wire to the case of the receptacle. Next align the dimple of the ground wire with the set screw. Using the appropriate torque wrench, tighten the set screw on the center ground wire to, 100 inch pounds (60 amp) or 20 inch pounds (30 amp). *********************************************************************** * NOTE * * The torque wrench provided in P/N 29-20906-00 must be properly * * set and "cocked" prior to use. Read the instructions accompanying * * this tool thoroughly. Dial in the proper torque value. Holding * * the torque wrench with its bit drive facing away from you, assure * * the rachet lever is set to the left and that the entire rachet * * head is "cocked" to the right. The wrench is now ready for * * tightening the Russellstoll pressure screws to the proper torque. * * Once the racket head has clicked from its cocked position, proper * * torque has been reach. Continued force will damage the tool and/ * * or the pressure screws. * *********************************************************************** 9. Connect (3) mounting screws and (1) bolt w/chain attached, located on the receptacle part of the BC29A-xx cable. ********************************************************* * WARNING * * The GREEN bonding wire MUST stay ATTACHED to the * * CASING of the Receptacle, thus bonding the case to * * the grounding conductor sleeve. * ********************************************************* 10. Perform POWER UP procedure (refer to Section #5, of this procedure). 11. Return the receptacle and sleeve to the branch office from which it was obtained for proper control of non-conforming materials. _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 11 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ SECTION #5; Power Up Procedure 1. Connect the KA86 power cord to its mating receptacle. 2. Locate the Branch Circuit (Mains) Disconnect Device and set it to the ON (1) position. The pilot lamps on the 876-A should light. 3. Open the front panel door and set the Main Circuit Breaker (CB1) of the 876-A Power Controller to the ON (1) position. 4. Power ON the VAX 86XX, by turning the SCP Terminal Control Switch to the Restart BOOT and LOCAL positions. 5. Re-boot VMS operating system and run one ERROR free pass of the UETP SYSTEM EXERCISER (if applicable). 6. For ULTRIX operating systems, run an ERROR Free pass of the SYSTEM EXERCISERS, applicable to your system, found in the /usr/field directory. The system exercisers are: cmx(8) tests terminal communications system dskx(8) tests disk drives fsx(8) tests the file systems lpx(8) tests the line printers memx(8) tests the memory mtx(8) tests the magnetic tape drives netx(8) tests the TCP/IP network system ************************************************* * NOTE * * Use online help (-h) for more information. * * Example: # dskx -h * ************************************************* 7. Have Customer verify that the system is operational. 8. Enter the change in the Site Management Guide (i.e. up-date the revision chart, note actions taken). 9. Fill out a LARS report (see Samples at the end of this document). 10. Forward ALL non-conforming materials to the Digital Branch for proper disposal and record keeping. _ _ _ _ _ _ _ | FCO KA86-M008 | | | | | | | | | |d|i|g|i|t|a|l| | PAGE 19 OF 19 |_|_|_|_|_|_|_| | | _______________________________|_________________________________________ LARS Activity DEC Type Action FCO # Material Option of Taken Comments Used Call ***************************************************************************** For Contract and Warranty Customers U.S. and G.I.A. W Option # M D FCO # EQ Kit # KA86 KA86-M008 EQ-01432-0X ***************************************************************************** For Per Call Customers U.S., G.I.A F Option # M D FCO # EQ Kit # KA86 KA86-M008 EQ-01432-0X ***************************************************************************** For Contract and Warranty Customers Europe Y Option # M I FCO # EQ Kit # KA86 KA86-M008 EQ-01432-0X ***************************************************************************** For Per Call Customers Europe F Option # M I FCO # EQ Kit # KA86 KA86-M008 EQ-01432-0X ***************************************************************************** \^ KA86 \\KA86 \\CYGAN \\1986 \\SEP \\FCO_DOCS