MAI COMPANY CONFIDENTIAL FIELD INFORMATION BULLETIN SERVICE GROUP(S): MINI MFG: CALCOMP NACS TYPE(S): 4500,4504 MFG. MODEL(S): T-80,T-83 CATEGORY: DISK I/O DESC: TRIDENT SERIES *** TABLE OF CONTENTS AS OF 06/01/93 *** FIB 00001.General Information.........................................10/14/86 FIB 00002.ERROR 4s caused by arcing across speed transducer...........05/23/80 FIB 00003.Information on the two different drive motor types..........04/01/81 FIB 00004.Earth ground jumper (on the power supply) information.......10/23/81 FIB 00005.Unexplained emergency retracts and/or sequence up problems..10/23/81 FIB 00006.ERROR 4, Disk 0, Sector 1 on BOSS load of OS 4.2 & later....02/16/82 FIB 00007.Procedure for converting from T-80 to T-83..................07/16/82 FIB 00008.New style cover latch may cause drive not ready problems....09/21/82 FIB 00009.Belt slippage requires new pulley...........................10/12/82 FIB 00010.Miscellaneous drive errors may be caused by wiring shorts...12/01/82 FIB 00011.T-83 Seek Velocity adjustment...............................05/26/83 FIB 00012.Mandantory ECN for T-83 Logic II - Rev D to Rev E...........05/26/83 FIB 00013.Connector problem on the Sequence Relay Assembly............07/25/83 FIB 00014.Read/write head mounting screw torque specification change..08/09/83 FIB 00015.Cleaning of spindle threads information.....................09/02/83 FIB 00016.Alignment meter connector - interference with capacitor.....09/02/83 FIB 00017.Maximum allowable defective tracks on Trident packs.........09/02/83 FIB 00018.Head crashes, pack damage and failure to emergency retract..09/02/83 FIB 00019.Squeal from linear motor due to incorrect capacitor in power11/16/83 FIB 00020.Incorrect failing sector numbers are reported by OMS Level 301/11/84 FIB 00021.Logic I below LARL can cause R/W errors with status of 8100002/28/84 FIB 00022.Spindle alarm doesn't work after upgrade from T-80 to T-83..04/12/84 FIB 00023.Read/write clock frequency adjustment proceedure............05/15/85 FIB 00024.Ferro resonant transformer - field test/repair proceedures..07/24/85 FIB 00025.R/W head tightening tools - usage information and part numbe08/15/85 FIB 00026.Power supply failures can be field repaired (capacitors)....10/14/85 FIB 00027.UPTIME can erroneously show the T-80 failed.................12/05/85 FIB 00028.Common R/W head part numbers between T-80/T-83 and T-303....02/11/86 FIB 00029.Logic I PCBA and Formatter-Radial PCBA compatabilities......03/07/86 FIB 00030.Read/write head part number to vendor number clarification..04/03/86 FIB 00031.Caution when making adjustments using the disk exerciser....08/26/86 FIB 00032.T80/83 linear motor repair parts available..................03/09/87 FIB 00033.Disk Pack Refurbishing & Formatting Procedure...............03/07/88 FIB 00034.Blower Motor Failures due to 240V Strapping [ WPSF 604 ]...03/05/90 FIB 00035.FAILURE TO LOAD HEADS AFTER SERVO HEAD REPLACEMENT..........04/21/93 DISK I/O-CALCOMP-T-80,T-83--------------------------Table Of Contents Pg01 of 01 FIB 00001 10/14/86 *** General Information *** UNFORMATTED INFORMATION: Number of cylinders......... 816 Tracks per cylinder......... 5 Bytes per track............. 20,160 Bytes per cylinder.......... 100,800 Bytes per pack.............. 82,252,800 bytes FORMATTED CAPACITIES: Basic.Four markets this machine in two basic models: 4500 (T-80) and 4303 (T-83) Model 4500 (T-80) capacity information: When the disk pack is formatted for use on the Basic Four Systems, each track is divided into 18 sectors of 1024 bytes each. Capacities shown are limited (when installed on Basic Four BBIII/BBIV Systems) by the operating system (BOSS), firmware on the Formatter Radial PCBA and, in some cases, by the Logic I PCBA in the drive, by limiting the number of sectors accessable. There are three configurations available: 20 Megabytes on 19620 sectors 35 Megabytes on 34200 sectors 75 Megabytes on 72720 sectors Model 4303 (T-83) capacity information: This Basic Four model is used on the 810 and MPx systems. The approximate capacity is 75 Megabytes. *** NACS MACHINE TYPES AND FEATURE NUMBERS *** 4283,4303 *** AVAILABLE DOCUMENTATION *** Basic Four Models 4504 and 4500 Maintenance Manual....S-HDBK-B34 *** AVAILABLE TRAINING *** Formal training is available as a part of Basic Four BBIII/BBIV school *** SPECIAL TOOLS *** Description Part Number ------------------------------------------------------------------------------- PCBA Extender ...............................................MM249010/12427-001. Tool, Head Positioning ......................................MM249020/17209-001 Tool, Head Preposition ......................................MM249030/97769-001 Torque Wrench, HD Mount (fixed at 6.5 in/lbs)................MM249135 Pin, Safety .................................................MM249050/97722-001 Tool, Tach Rod Insertion/Removal ............................MM249060/13445-001 Wrench, Way Screw ...........................................MM249090/99129-001 Tool, Head Camming ..........................................MM249110/96803-001 Torgue Wrench, Carriage/Way .................................MM249130/TQ5-6-FU Bit, Hex Key 3/32 (straight-tipped 1/4" drive)...............MM249195 Fixture, Alignment Carriage/Way .............................MM249210/17585-001 Tool, Head Support ..........................................MM249220/10076-001 Exercisor, Sorbus Manufactured ..............................0R997565 Alignment Pack ..............................................MM249100 DISK I/O-CALCOMP-T-80,T-83--------------------------FIB001 Pg001 *** SPECIAL ADMINISTRATIVE PROCEEDURES *** none ORIGINATOR: J. WHALEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB001 Pg002 FIB 00002 05/23/80 *** ERROR 4s caused by arcing across speed transducer *** The distance between the pulley and Speed Transducer has been increased to eliminate intermittent problems caused by arcing between AC and DC ground at the Speed Transducer. The Speed Transducer shall be mechanically adjusted to obtain a gap of 0.006+ .001 inches between the pulley and the transducer. After this adjustment is performed, the transducer output should be greater than 5.0V peak to peak at operating speed. Check output at connector backplane pin 6B13. If a minimum of 5.0V cannot be attained with this new adjustment, replace the transducer. Correct Service Manual Model 2500, BFC 8006 page 4-61/62 to reflect these changes. ORIGINATOR: H. MONTIJO DISK I/O-CALCOMP-T-80,T-83--------------------------FIB002 Pg001 FIB 00003 04/01/81 *** Information on the two different drive motor types *** There are two different brands of drive motors in the field: Motronics (old style) - MM244070 General Electric (new style) - MM244075 If it is necessary to substitute the G.E. type for the Motronics type, the drive power supply must be at or above revision Z and the Logic III PCBA must be at or above revision P. If these revision levels are not met, the spindle brake will not function. ORIGINATOR: D. GOEHRISCH DISK I/O-CALCOMP-T-80,T-83--------------------------FIB003 Pg001 FIB 00004 10/23/81 *** Earth ground jumper (on the power supply) information *** On the power supply of the Trident series disk drive, near the AC terminal block, TB2, is located a green wire jumper. This jumper is connected to earth ground via the power plug. There are two tabs on the PCB to which this jumper may be connected. One tab is marked "OPEN" and the other is marked "CLOSED". To lessen the possibility of ground loops, this jumper must be plugged to the "OPEN" tab. When jumpered to the "CLOSED" tab, the system Logic Ground is thereby connected to earth ground at that point, forming a ground loop. *** CAUTION *** If the disk drive is ever powered up while disconnected from the system (for service), this jumper must then be connected to the "CLOSED" tab to prevent a safety hazard. If left in the "OPEN" position, a potential as high as 60 volts could develope between Logic Ground and the disk drive frame. ORIGINATOR: TIC CENTER DISK I/O-CALCOMP-T-80,T-83--------------------------FIB004 Pg001 FIB 00005 10/23/81 *** Unexplained emergency retracts and/or sequence up problems *** Electrical noise on the DC Unsafe latch circuit can cause the above failure symptoms. If you are experiencing these problems, power down the drive, remove the Servo Control PCBA an check the following: 1. Locate IC chip A29. 2. Check for a jumper between IC A29 pins 2 and 12. 3. Check for a jumper between resistors R115 and R196. If present this jumper will be located on the componant side of the PCBA, on the ends of the resistors nearer to the top of the PCBA. If you find that neither of the above mentioned jumpers exist, add a jumper as described in step 3. and mark the PCBA with "DT076". ORIGINATOR: TIC CENTER DISK I/O-CALCOMP-T-80,T-83--------------------------FIB005 Pg001 FIB 00006 02/16/82 *** ERROR 4, Disk 0, Sector 1 on BOSS load of OS 4.2 & later *** SYMPTOM: Error 4, Disk 0, Sector 1 during OS load of level 4.2 or later. This only applies to drives connected to Basic Four 13XX systems. FIX: Adapter buss PCBA (MM820050, 901970) must be at Rev P or later. THIS IS A VERY IMPORTANT REVISION AS FILE DAMAGE IS LIKELY IF AN EARLIER REVISION BOARD IS USED!!! ORIGINATOR: P. DOBROW DISK I/O-CALCOMP-T-80,T-83--------------------------FIB006 Pg001 FIB 00007 07/16/82 *** Procedure for converting from T-80 to T-83 *** Basic Four Model: 4500 to 4504 This bulletin contains the information needed for converting the 4500 ( Calcomp T-80) disc drives presently used on the 610/730 systems to 4504 ( Calcomp T-83 ) T-83 ) for use on a 810 or MPx system. The conversion cannot be made on T-80 drives with vendor serial number 491 or below. Conversion kit MBF Part Number 907192-001 consists of the following: QTY. DESCRIPTION VENDOR PART NO. 1 Card Cage 24079-001 1 Logic I PCBA 24050-001 1 Logic II PCBA 24063-001 1 Lens Cap 92968-026 1 Terminator 24102-001 6 Tie Wrap 221004-000 5 Jumper Pin 302000-001 Return removed parts through normal parts procedures, indicating that they are good spares. CONVERSION PROCEDURES 1. Power OFF the drive, and disconnect the AC power cable. 2. Remove the rear cover. 3. Remove all circuit cards from the card cage, keeping them in order for proper re-installation. (See Figure 1). 4. If present, remove all interfacing cables and/or terminator from card cage connectors J2, J3 and J4 and return to stock. Also, disconnect the ground strap from GND lug E11. (See Figure 1). 5. Unlatch the card cage assembly and swing it up to its open position. Disconnect P5, P6 and P7 on the side of the card cage facing the linear motor and cut the three plastic tie wraps holding the P5, P6 and P7 cables to the assembly. (See Figure 1). 6. When viewing the bottom of the card cage, notice several multi-wire cable and separate wires are connected directly to backplane PCB card connectors.. Disconnect and tag each of these wires/connectors with the connector pin number from which they were removed. Cut the three tie wraps and remove the screw securing the cable clamp that hold the disconnected cables to the card cage assy. (See Figure 2). 7. Disconnect the Molex connector P8, located at the bottom of open card cage. Also, disconnect the ground strap adjacent to this connector. (See Figure 2) 8. Disconnect the restraining cable from the top end of the card cage assembly and swing the assembly to its closed position. (See Figure 2.) 9. Remove the three screws attaching the card cage assembly bottom hinge to the frame and lift the assembly free and clear. (See Figure 1). 10. Use the above procedures in reverse order to re-assemble the card cage assembly with the following exceptions: A) Re-install using the new card cage. B) Before installing the PCB modules, replace the Logic I and Logic II PCB modules with the new logic modules. Install sector jumpers on Logic III PCB module as shown in Figure 3 and set the device address Switch 1 on Logic I PCB module for the appropriate unit number, all open for Drive 0, POS 1 closed for Drive 1. NOTE: When re-installing the PCB modules, reference Figure 1 for proper slot location and install with the component side facing the power supply. DISK I/O-CALCOMP-T-80,T-83--------------------------FIB007 Pg001 CABLE PROCEDURE 1. Reference Figure 4 for proper cable sequence. --- Figure 3 --- CABLE KEY LENGTH (FT) BFISD P/N ------------------------------------------------------------------- R1 RADIAL CABLE, (STANDARD) 1st. 35 907111-003 R1 RADIAL CABLE, (OPTIONAL) 2nd. 60 907111-004 M1 BUS CABLE, DRIVE/DRIVE 20 906608-003 M2 BUS CABLE, (STANDARD) 1st. 35 906608-006 M2 BUS CABLE, (OPTIONAL) 60 906608-007 EXTERNAL SEQ (STANDARD) 35 907140-002 (S) EXTERNAL SEQ (OPTIONAL) 60 907140-003 EXTERNAL SEQ DRIVE/DRIVE 20 907140-001 (T) TERMINATOR DRAWING INFORMATION: Refer to TSIB 03-314 for figures. ORIGINATOR: J. KANZLER DISK I/O-CALCOMP-T-80,T-83--------------------------FIB007 Pg002 FIB 00008 09/21/82 *** New style cover latch may cause drive not ready problems *** The newer Model 25xx Removable Media Disc Drive cabinets employ a non-metal cover release latch. These new latches may cause drive ready problems if improperly adjusted in conjunction with the positioning of the cover latch micro switch. When installing disc units or encountering intermittent drive ready or read errors, verify that the cover latch micro-switch is fully engaged. The latch mounting bracket screws allow for adjustment to ensure proper cover closure. ORIGINATOR: J. RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB008 Pg001 FIB 00009 10/12/82 *** Belt slippage requires new pulley *** If you are experiencing belts slipping off or have replaced a spindle motor and are having belt problems, check the manufacturer of the spindle motor. If it is a Robbins & Meyers motor, Rev E, replace pulley with MM244910. ORIGINATOR: J RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB009 Pg001 FIB 00010 12/01/82 *** Miscellaneous drive errors may be caused by wiring shorts *** SUBJECT: Trident disc drive internal cables MBF models 4500 & 4504, Sorbus models 4283 & 4303 Cases have been found in the Model 4500/4 disc drive where the cabling has been damaged due to the route the cable makes in the area below the absolute filter. Normal disc vibration may cause wire insulation wear and/or cable pinching causing intermittent errors such as dropping ready. Whenever the filter is replaced, the cabling should be visually checked for indications of this problem. Where necessary, re-route the cable as shown below using the existing tie-wrap mounts and an appropriate adhesive (quick-dry epoxy or Eastman 910 or equivalent). DRAWING INFORMATION: See Mini Alert 86 hardcopy for drawing. ORIGINATOR: J. RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB010 Pg001 FIB 00011 05/26/83 *** T-83 Seek Velocity adjustment *** The backplane pin to be used when making the Seek Velocity adjustment has been re-located on the T-83 versus the T-80. The signal used is RDY. It is located on pin 3B11 on T-83's. This signal is found on pin 3A48 on T-80's. This change is incorporated in the combined T-80/T-83 Maint. Manual S-HDBK-B34. ORIGINATOR: J. VANDERHEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB011 Pg001 FIB 00012 05/26/83 *** Mandantory ECN for T-83 Logic II - Rev D to Rev E *** Century Data has released an engineering change to the T-83 Logic II PCBA to correct a marginal timing condition on the Write Data driver gating. The change requires one etch cut and one jumper, and can be field-installed in order to expedite it. Following are PCBA identification and rework instructions. Logic diagram corrections are attached. Part number Revision Level Manufacturer/Sorbus Description Old New ------------------------------------------------------------------ 24063-001/MM245010 Logic II PCBA (T83) /D /E REWORK INSTRUCTIONS 1) Cut etch on solder-side at IC 5E pin 04. 2) Add 30 ga. insulated wire on component side from IC 3D pin 10 to 5E pin 04. 3) Change PCBA Revision marking to 24063-001/E 4) If you have Century Data logics, correct Logic Drawing LD8.1 per the attached sheet. This change will be reflected in the combined T80/T83 Service Manual BFISD 8006B printed 4/15/83. 5) Record your time as Service Code 09 LOGIC DRAWING LD8.1 DRAWING INFORMATION: See Mini Alert 145A hardcopy for drawing. ORIGINATOR: J. VANDERHEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB012 Pg001 FIB 00013 07/25/83 *** Connector problem on the Sequence Relay Assembly *** There is a potential problem caused by the stiffness of the cable harness to connector P21 on the sequence relay assembly. When this assembly is swung open for servicing, P21 can back out of or become cocked in connector J21. This can cause the drive to fail to sequence up or to drop READY during operation. Each time te sequence relay assembly is moved, P21 shoul be checked for proper seating in J21. ORIGINATOR: J. VANDER HEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB013 Pg001 FIB 00014 08/09/83 *** Read/write head mounting screw torque specification change *** The torque specification for head mounting screws on all Calcomp drives (T-80, T-83, and T-303) has been changed to 104 inch-ounces. Although the torque screwdriver used by Sorbus is nominally calibrated to 100 inch-ounces, it can be set for 104 inch-ounces within its adjustment range and performs satisfactorily. Change all service documentation to reflect the new torque requirement. Actual head torque should only be changed in the process of performing head alignment. NOTE: When any torque wrench or screwdriver utilizing an adjustable pre-load spring is stored, the torque adjustment should always be set to its lowest setting to prevent premature loss of calibration. ORIGINATOR: J. VANDERHEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB014 Pg001 FIB 00015 09/02/83 *** Cleaning of spindle threads information *** In the maintenance manuals of the Trident series disk drives supplied by Basic Four, a paragraph is dedicated to the cleaning and lubrication of the spindle. The manual states that during periodic maintenance, Sta-lube molybdenum grease should be used on the disk pack mounting spindle threads. This procedure is INCORRECT! The only maintenance required is the cleaning of the spindle mounting threads with alcohol applied with a cotton swab. Please delete paragraph 5 under heading 4.2.2.3 (page 4-6) of BFISD 8006P, Volume I. ORIGINATOR: CENTURY DATA DISK I/O-CALCOMP-T-80,T-83--------------------------FIB015 Pg001 FIB 00016 09/02/83 *** Alignment meter connector - interference with capacitor *** Newer Century Data T2001 alignment meters have a connector with unused pins to prevent misplugging and subsequent damage. This connector may interfere with a capacitor (C45) on older Read/Write Matrix PCBAs. If this condition is encountered, DO NOT cut off the usused portion of the meter connector. Instead, unsolder one side of the capacitor and extend it with solid wire. Insulate the added wire with vinyl "spagetti" or heat shrink tubing and re-install it at an angle so as to clear the new connector. ORIGINATOR: J. VANDER HEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB016 Pg001 FIB 00017 09/02/83 *** Maximum allowable defective tracks on Trident packs *** Maximum Field Diagnostic Defective Spare Spare Disk Tracks Tracks Tracks System Capacity Allowed Available Available ------------------------------------------------------------------------ BBIII/BBIV 75MB 35 0 0 MPx 75MB 35 60 0 MPx 300MB 60 73 0 ORIGINATOR: TIC CENTER DISK I/O-CALCOMP-T-80,T-83--------------------------FIB017 Pg001 FIB 00018 09/02/83 *** Head crashes, pack damage and failure to emergency retract *** The above symptoms can result if the connector between the main power transformer and the power supply PCBA becomes partially unplugged. In one incident, this condition caused damage to several Servo Control PCBAs as well. Under most circumstances, the DC Unsafe detection circuits will prevent such damage, but in this case, even the Emergency Retract function failed. Although the connector in question is a locking type, it has been found unlatched after shipment or servicing and in some cases proved extremely difficult to latch due to the stffness of the transformer leads and their short length. Ensure that this connector is fully seated and latched in order to prevent the serious potential of damage. ORIGINATOR: J. VANDER HEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB018 Pg001 FIB 00019 11/16/83 *** Squeal from linear motor due to incorrect capacitor in power supply *** Recently, there were several T80/83 Power Supply/Power Amplifiers (Part number 12449-002/MM240010) which were marked Revision AK, but which had the 100 picoFarad capacitor in location C13 rather than the 10 picoFarad called out for that revision by Century Data on Field Change DT101. The incorrect capacitors are identified by the marking 101K. The correct ones are marked 100K (the third digit is a multiplier). Figure 1 shows the location of C13 on the Power Supply/ Power Amplifier PCBA. The field change in question was to correct 'squeal' from. the linear motor resulting from Op Amps in location A1 having slow rise time. Inspect your spare Power Supplies as well as those installed in drives exhibiting any 'squeal' from the linear motor. Supplies found to have the incorrect capacitor should be repaired with locally-purchased components or returned to NACS WEST with the discrepancy noted on the DMT. Capacitor C13 Should be 10 pF (marked 100K) DRAWING INFORMATION: See Mini Alert 204 hardcopy for drawing. ORIGINATOR: J. VANDERHEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB019 Pg001 FIB 00020 01/11/84 *** Incorrect failing sector numbers are reported by OMS Level 3.0 *** Level 3.0 OMS software reports disk errors by disk number, sector number and disk status. There is, however, a programming error in computing the sector number which may result in reporting the incorrect sector number when an error occurs. The following indicates the sector number formula: As implemented: Sector no. = STR(TCB(1)*256+INT(TCB(2)/256)) Should be: Sector no. = STR(INT(DEC(BIN(TCB(1),2)+BIN(TCB(2),2))/256)) Since this formula is used in most OMS programs using disk access, it is impractical to effect a field correction to the problem. However, be aware that if a disk error is reported, and no problem is found on the reported sector, ADD 255 to the reported sector number and check that sector or the file containing that sector for errors. ORIGINATOR: J. RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB020 Pg001 FIB 00021 02/28/84 *** Logic I below LARL can cause R/W errors with status of 81000000 *** If diagnostics or the error log show that a T-83 or T-303 is having recoverable read or write errors with a hex status of "81000000". ID sync error, check the revision level of the Logic I board. Model MFG P/N Sorbus P/N LARL ----------------------------------------------- T-83 24050-001 MM245000 D T-303 16407-001 MM246040 D If the Logic I board is a revision level C the change can be installed in the field. The change is one cut and one jumper. T-83 Logic I 24050-001 Remove HDSEL/ from output of 8D pin 8. Ground HDSEL/ at connector B06 on the logic board. Change the revision level of the board to Rev. D. Revise logic diagram to reflect the change per attached diagram. T-303 Logic I 16407-001 Remove HDSEL/ from input of 7A pin 13. Ground HDSEL/ at 7A pin 13. Change the. revision level of board to Rev. D. Revise logic diagram to reflect the change per attached diagram. NOTE: If you do not understand the rework instructions or do not wish to do it return the board and specify reason for return is LARL. DRAWING INFORMATION: See Mini Alert 231 hardcopy for drawing. ORIGINATOR: J. KANZLER DISK I/O-CALCOMP-T-80,T-83--------------------------FIB021 Pg001 FIB 00022 04/12/84 *** Spindle alarm doesn't work after upgrade from T-80 to T-83 *** The card cages sent with the T-83 upgrade kits may be wired for the Lid Lock feature rather than the Spindle/Cover Alert feature. Since the T-80 drives do not have a lid lock, a card cage wired for the Lid Lock feature will not sound the alarm if the cover is raised while the disk pack is rotating. This presents a potential safety hazard to the operator. A card cage wired for the Lid Lock feature has a wire from J6, pin 25 connected to card slot 5A, pin 10. To change the card cage to the Spindle/Cover Alert feature, change this wire so that it connects J6, pin 25 to card cage slot 5A, pin 25. This will cause the alarm to sound when the cover is raised while the spindle is spinning. It should also be noted that if a T-83 drive from the factory has a Lid Lock and it is inoperative, this may be caused by the card cage being erroneously wired for the Spindel/Cover Alarm feature. In this case the above mention wiring change must be reversed. ORIGINATOR: S. SCHWARTZ DISK I/O-CALCOMP-T-80,T-83--------------------------FIB022 Pg001 FIB 00023 05/15/85 *** Read/write clock frequency adjustment proceedure *** SUBJECT: R/w clock frequency adjustment (possible cure for image backup problems on the MPx Systems) There seems to be some confusion about the adjustment procedure the the R/W Clock. The following is an attempt to clarity the procedure and its intended results. After setting up scope and drive according to Service Manual, manually move the heads to the vicinity of Cylinder 0 (about an inch forward of the head load area). Adjust the horizontal position control of the scope so that the trailing edge of the last pulse crosses the center lines of the scope - see Figure 1. Now move the heads all the way toward the spindle and notice the shift of the signal to the right. Note the exact point that the trailing edge of the last pulse crosses the horizontal center line - see Figure 2. Now move . the heads away from the spindle until the head arms barely touch the lifting cams. At this point, the trailing edge of the last pulse should cross the horizontal center line at a point between Cylinder 0's and Cylinder 800's - see Figure 3. If this condition does not exist, adjust R14 to meet these criteria. DRAWING INFORMATION: See Mini Alert 358 hardcopy for figures mentioned in the text. ORIGINATOR: S. SCHWARTZ DISK I/O-CALCOMP-T-80,T-83--------------------------FIB023 Pg001 FIB 00024 07/24/85 *** Ferro resonant transformer - field test/repair proceedures *** The Transformer Assembly (MM240430) is most often replaced for low unregulated voltages (+9, +30 and -30 volts) which cause ripple on the regulated voltages (usually the +5), or for 'dropping ready' due to some type of Actuator malfunction. The only component on the Transformer Assembly known to fail periodically is the oil-filled capacitor used in the ferro-resonant regulation circuit. This capacitor can and should be field-replaced. The process of diagnosing capacitor failure is relatively simple. 1. Measure the unregulated +9 volts on the collector (case) of the +5 volt regulator pass-transistor mounted on the card cage frame. It should measure approximately +10 volts plus or minus 0.5 volt with all the PCBAs in the machine (approx. 1v ripple). If the +9 volts is too high (>11 volts), the capacitor is good, but the voltage-tap configuration is probably wrong for the customer's line voltage. This condition will overheat the pass-transistor. Consult the Service Manual and re-wire the voltage taps as required. If the +9 volts is +9.5 to +11 volts, measure the +30 volts and -30 volts at the collectors (cases) of the Servo Power Amplifier output transistors. The normal range of the +/-30 volts is 36 to 40 and very nearly balanced. If the +9 and both 30 volt supplies appear to produce the proper voltages, the Transformer Assembly is working correctly. CAUTION! THE FOLLOWING PROCEDURE INVOLVES HAZARDOUS VOLTAGES. USE EXTREME CARE TO AVOID RISK OF INJURY AND/OR ELECTRICAL SHOCK. If all three bulk supply voltages are low, then the capacitor is highly suspect. To further prove this theory, turn off the drive and DISCONNECT INPUT POWER. Unplug one of the capacitor leads, carefully insulating it from all surfaces. Reconnect the power and turn on the drive. With the capacitor disconnected, the +9 and +/-30 volt supply voltages should measure at least 10% to 15% lower at all outputs. If it does not, the capacitor is probably defective and should be replaced. Sorbus ICN Vendor P/N Description -------------------------------------------------------- YY016071 90357-415 Capacitor, paper/oil ORIGINATOR: J. RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB024 Pg001 FIB 00025 08/15/85 *** R/W head tightening tools - usage information and part numbers *** The tools currently being used by the field to tighten R/W heads on removable media, Century Data disk drives are an adjustable torque wrench, MM249130 with a 3/32" hex, ball-tipped bit, MM249190. Century Data has informed us that the ball-tipped bit is not adequate. A straight-tipped bit should be used. Straight-tipped bits may be ordered, Code C. The assigned ICN is MM249195. Although the accuracy of the adjustable torque wrench has been questioned, as the required setting exceeds its maximum scale, an estimated setting of the desired value is generally adequate. (Top scale of wrench is 100 in./ozs., required torque is 104 in./ozs.) It has also been noted that repeated adjustment changes over a period of time will vary the calibration of the wrench. A fixed-value torque wrench, to be dedicated for use on these drives, may be ordered, ICN MM249135. This wrench is considerably shorter than the adjustable one, therefore a little easier to use. The wrench may also be used to tighten the tach rod, as the required torque is . the same, i.e., 104 in./ozs. or 6.5 in./lbs. (The service manual lists an incorrect value for this setting.) The straight-tipped bit mentioned above will fit either the fixed or the adjustable torque wrench. Tools for T-80, T-83, T-303 disk drives Torque wrench, fixed value 6.5 in./lbs. MM249135 (Usage: as required) Bit, hex 3/32", straight-tipped, 1/4" drv. MM249195 (Usage: mandatory) ORIGINATOR: C. GAHAN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB025 Pg001 FIB 00026 10/14/85 *** Power supply failures can be field repaired (capacitors) *** Problem : T80/83 Power Supply (MM240010) faults are mainly due to capacitor failures which may be replaced in the field. Solution : Verify capacitors for proper operation as listed below. Replace as required upon failure (observe polarity). CAP. DESCRIPTION NOM. V. TYP. RIPPLE ICN VENDOR # DESCRIPTION ---- ----------- ------- ----------- -------- --------- ----------- C2 Emer. Retct - 8V * -- YY008677 91810-156 35KMF 15V C5 -30V Unreg. -30V 150 mv YY006816 91810-404 32KMF 40V C6 +30V Unreg. +30V 150 mv YY006816 91810-404 32KMF 40V C7 + 9V Unreg. + 9V ** 1 v YY006808 91810-152 16KMF 15V * If CPU is OFF, DEGATE drive. ** Most common failed component. ORIGINATOR: J. RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB026 Pg001 FIB 00027 12/05/85 *** UPTIME can erroneously show the T-80 failed *** PROBLEM: UPTIME may report a removable disk drive as "FAILED" although the system is operating properly. SOLUTION: UPTIME tests 4 cylinders of a drive for a 1350 CPU and 64 cylinders for a non-High Speed CPU. Since UPTIME firmware constraints did not allow space to deal with alternate tracks, the display will report the drive as having failed UPTIME. This reported 'Failure' does not therefore indicate a real problem if an alternate track within the range of tested cylinders is encountered. Page 4 of the customer's UPTIME instruction book states that the FE "will determine if a hardware problem exists". Keep the above information in mind during this determination. ORIGINATOR: J. RIPPL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB027 Pg001 FIB 00028 02/11/86 *** Common R/W head part numbers between T-80/T-83 and T-303 *** Century.Data Systems has two different part numbers assigned to the T-80/83/303 Read/Write heads. They are interchangeable. The difference is that the 17835-xxx heads are manufactured using closer tolerances. This in no way affects the operation of the drive. The ICN number is the same for both heads. T-303 T80/83 Head Head ICN Part Numbers AMC P/N Description Positions Positions -------- ------------------- ---------- ------------ ----------------- --------- MM246180 18507-001/17835-001 333239-100 R/W Head Asm 3, 7, 9, 13, 17 MM246190 18507-002/17835-002 333239-200 R/W Head Asm 1, 5, 11, 15 MM240330 18507-003/17835-003 333239-300 R/W Head Asm 2, 6, 10, 14, 18 1, 4 MM240340 18507-004/17835-004 333239-400 R/W Head Asm 0, 4, 8, 12, 16 0, 3 MM246170 13500-001/17841-005 331137-504 T303 Servo Hd MM240350 18508-006 339239-101 MM240360 13502-001 331137-502 Century.Data Systems has two different part numbers assigned to the T-80/83/303 Read/Write heads. They are interchangeable. The difference is that the 17835-xxx heads are manufactured using closer tolerances. This in no way affects the operation of the drive. The ICN number is the same for both heads. T-303 Head T80/83 Head ICN P/N's AMC P/N Description Positions Positions -------- ---------- ---------- ------------ ---------------- ----------- MM246180 18507-001, 333239-100 R/W Head Asm 3, 7, 9, 13, 17 17835-001 MM246190 18507-002, 333239-200 R/W Head Asm 1, 5, 11, 15 17835-002 MM240330 18507-003, 333239-300 R/W Head Asm 2, 6, 10, 14, 18 1, 4 17835-003 MM240340 18507-004, 333239-400 R/W Head Asm 0, 4, 8, 12, 16 0, 3 17835-004 MM246170 13500-001, 331137-504 T303 Servo Hd 17841-005 MM240350 18508-006 339239-101 MM240360 13502-001 331137-502 ORIGINATOR: J. BUSCAGLIA DISK I/O-CALCOMP-T-80,T-83--------------------------FIB028 Pg001 FIB 00029 03/07/86 *** Logic I PCBA and Formatter-Radial PCBA compatabilities *** OLD SYSTEMS NEW SYSTEMS System 730 System 730 Model 2580 Disk Drive(s) Model 2580 Disk Drive(s) Formatter Radial 901930, MM820010 Formatter Radial 901930, MM820010 2950 Disk Pack (75MB) 2950 Disk Pack (75MB) Logic I 12342-001, MM240030 Logic I 12342-001, MM240030 System 610 System 610 Model 2530 Disk Drive(s) Model 2530 Disk Drive(s) Formatter Radial 901930, MM820010 Formatter Radial 903279, MM821010 2935 Disk Pack (35MB) 2935 Disk Pack (35MB) Logic I 903050, MM240460 Logic I 12342-001, MM240030 System 510 System 510 Model 2520 Disk Drive(s) Model 2520 Disk Drive(s) Formatter Radial 901930, MM820010 Formatter Radial 903280, MM842010 2935 Disk Pack labeled 2920 2950 Disk Pack (75MB) Logic I 903050, MM240460 Logic I 12342-001, MM240030 For compatibility with adjustment/alignment procedures and diagnstics, convert the Logic I PCBA, P/N 903050, MM240460 to P/N 12342-001, MM240030. Remove the jumpers on the IC chip at location 1C from pins 4,5,7,10 and 11. Add jumpers (where etches were cut at 1C) as shown below. FROM TO 1C-04 2C-04 (CAR 064) 1C-05 2C-06 (CAR 128) 1C-11 5B-05 (CAR 512) ORIGINATOR: TIC CENTER DISK I/O-CALCOMP-T-80,T-83--------------------------FIB029 Pg001 FIB 00030 04/03/86 *** Read/write head part number to vendor number clarification *** In an effort to meet the demand for T-80/83/303 R/W heads, we are buying them from several different sources. These include Century Data Systems, Basic Four, and also from Infoextend. Heads from Infoextend are marked with the Century Data part number. Century Data and Basic Four are buying them from Applied Magnetics Corp. (AMC) and, depending on who AMC has sold them to and when, they have assigned several different manufacturing part numbers to the same head, and the box may or may not be marked with the Century Data part number. As not all the heads are marked with the Century Data P/N, this is going to create a lot of confusion. The following list will attempt to alleviate some of it. .NACS CENT. DATA T-303 Head T80/83 Head ICN P/N's AMC P/N Description Positions Positions --------. --------- ---------- ------------ ---------------- ----------- MM246180 18507-001, 3332XX-1XX R/W Head Asm 3, 7, 9, 13, 17 17835-001 MM246190 18507-002, 3332XX-2XX R/W Head Asm 1, 5, 11, 15 17835-002 MM240330 18507-003, 3332XX-3XX R/W Head Asm 2, 6, 10, 14, 18 1, 4 17835-003 MM240340 18507-004, 3332XX-4XX R/W Head Asm 0, 4, 8, 12, 16 0, 3 17835-004 MM246170 13500-001, 3311XX-5XX T303 Servo Hd 17841-005 ORIGINATOR: C. GAHAN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB030 Pg001 FIB 00031 08/26/86 *** Caution when making adjustments using the disk exerciser *** When performing Data Separator board adjustments (data window, clock frequency and data window width), the Trident Disk Exerciser, under certain conditions, can cause the scope display to be very fuzzy and cause the R/W adjustments to be difficult or impossible to do properly. There are three options options which will eliminate this problem: 1. After manually loading the heads for the adjustments, issue a seek from the exerciser. Although the drive will not actually seek, read gate will be turned off, making the scope display "clean". 2. Prior to spinning the drive up, place the drive online to the system. 3. The exerciser can be disconnected from the drive during these adjustments. ORIGINATOR: H. MITCHELL DISK I/O-CALCOMP-T-80,T-83--------------------------FIB031 Pg001 FIB 00032 03/09/87 *** T80/83 linear motor repair parts available *** SYMPTOM: Defective/damaged Linear Motor electrical or mechanical components FIX: To avoid the shipping cost and damage in transit that usually occurs when T80/83 Linear Motors are shipped, NACS has the following parts available. Refer to BFISD 8006P vol. II figure 6-14 for illustrations: ITEM NACS ICN VENDOR PART # DESCRIPTION ---- ----------- ------------- ----------------------------------- 9 MM240376 12398-001 Block, Conductor Band 14 BN/MM244090 12390-001 Insulator, Linear Motor 15 BN/MM244040 12389-001 Conductor, Linear Motor 16 BN/MM244100 12390-002 Insulator, Linear Motor 17 BN/MM244050 12389-002 Conductor, Linear Motor 21 MM240377 12395-001 Terminal Block, Linear Motor 25 MM240375 12275-001 Bobbin Assy, Linear Motor ORIGINATOR: J. VANDERHEYDEN DISK I/O-CALCOMP-T-80,T-83--------------------------FIB032 Pg001 FIB 00033 03/07/88 *** Disk Pack Refurbishing & Formatting Procedure *** Sorbus is no longer refurbishing & reformatting Basic Four disk packs. The customer should contact the MAI Basic Four supply & distribution center at 1 800 854-8032 with the following information: Customer address Type of pack(s) (i.e. T80/T83/T303) Serial numbers(s) of pack(s) Quantity of packs to ship When the pack is received, MAI Basic Four will ship a replacement pack. NOTE: There may be some changes to the above procedure. The supply & distribution center will inform the customer of the current procedure. ORIGINATOR: Bob Berard DISK I/O-CALCOMP-T-80,T-83--------------------------FIB033 Pg001 FIB 00034 03/05/90 *** Blower Motor Failures due to 240V Strapping [ WPSF 604 ] *** Blower motors for drives that are configured for 240VAC are having a shorter life span than expected. The drive blower motors are rated at 115VAC or 208VAC respectively. When the drive is configured for 240VAC, the blower motor overheats and needs replacement more often. Drives that are configured for 240VAC should have the blower motor AC taps changed in the following way: T80/T83 (See figure #1) At the power supply, move TB2-03 to TB2-04. T303 (See figure #2) Re-route wire from J/P32-1 to P/J14-2 whenever P/J14-1 is used for 220VAC to 254VAC. DRAWING INFORMATION: See hard copy of FB 604 for figures. ORIGINATOR: Don Luque DISK I/O-CALCOMP-T-80,T-83--------------------------FIB034 Pg001 FIB 00035 MAI COMPANY CONFIDENTIAL 04/21/93 *** FAILURE TO LOAD HEADS AFTER SERVO HEAD REPLACEMENT. *** SYMPTOM/TEXT: After replacing a servo head on either a T80 or T303 disk drive, it is found that the heads will not load out through the load zone and lock on servo.as is normal. Upon further examination it was found the servo was emit- ting a clicking or buzzing sound. Pushing the servo forward (toward the spindle) made the frequency of the sound go up. Furthermore the servo was not "locking on track". It could be moved back and forth with some resistance. If the servo head was unplugged from the servo preamplifier, the heads could be pushed out in to the data area of the disk pack. If a tester was plugged in you could then make single track seeks forward and backward. Servo lock was achieved once the servo head was plugged back into the preamp. However, longer seeks resulted in a device check indicating an illegal cylinder/cylinder mismatch. This is normal since the servo system doesn't really know where it is at this point. FIX: This is a fairly rare condition that was created by the manufacturer. It was found that the servo head output was reversed. Apparantly a few machines were made that had a reversed pair of wires on the servo head. To correct this someone simply reversed the dibit wires coming frome the servo preamplifier. As far as the disk logic is concered it doesn't care as long as the polarity of the dibit is correct as it sees it. So, when the origional servo head went bad, and someone attempted to replace it with a servo head that's wired correctly; the disk drive would no longer load heads correctly. The drive logic tells the servo to move the heads to the load zone at load speed. Once in the load zone the drive logic sees the single polarity dibits and seeks forward to a null point (a positive and a negative dibit), and locks servo at that point. If the dibits are polarity reversed the servo logic attempts to pull the heads away from the spindle, but, load speed is up and the servo then drives back forward. At this point the servo sits and buzzes or clicks at the edge of the load zone. To correct this simply reverse the dibits at the card cage. These are a Black and a White wire. Pull them out and reverse them on the plug block. ORIGINATOR: Dennis Rydquist DISK I/O-CALCOMP-T-80,T-83--------------------------FIB035 Pg001