MAI COMPANY CONFIDENTIAL FIELD INFORMATION BULLETIN SERVICE GROUP(S): MINI MFG: CALCOMP NACS TYPE(S): 4502 MFG. MODEL(S): T-303 CATEGORY: DISK I/O DESC: 300MB REMOVABLE *** TABLE OF CONTENTS AS OF 06/01/93 *** FIB 00001.General Information.........................................09/19/86 FIB 00002.New Drive Motor Pulley Eliminates Belt Jumping Off..........10/12/82 FIB 00003.Preliminary Installation Instructions.......................03/21/83 FIB 00004.ECN to Upgrade the I/O PCBA from REV. B to REV. C...........05/26/83 FIB 00005.Information on Securing the Cable Grounding Straps..........09/23/83 FIB 00006.Read/Write Head Alignment Using Demon.......................11/03/83 FIB 00007.Miscellaneous Drive Failures due to Board Seating Problems..01/23/84 FIB 00008.Logic I Below LARL can Cause R/W Errors with Status of HEX 802/28/84 FIB 00009.Lowest Acceptable Revision List (LARL)......................05/15/85 FIB 00010.Read/Write Clock Frequency Adjustment Procedure.............05/15/85 FIB 00011.A/C Input Voltage Tap Setting...............................06/17/85 FIB 00012.Annual Preventive Maintenance Schedule......................07/02/85 FIB 00013.R/W Head Mounting Screw Torque Change & New Torque Wrench...08/15/85 FIB 00014.Check Input Transformer before Replacing the Power Supply...08/27/85 FIB 00015.Service Hints for -50 Volts DC Problems.....................10/22/85 FIB 00016.POTENTIAL.A/C VOLTAGE SHORT TO FRAME MISC.READ ERRORS.......05/04/88 FIB 00017.Information and Procedure on R/W Heads with Defective Cables12/11/85 FIB 00018.Braces Available for R/W Head Cables to Reduce Vibration & S12/18/85 FIB 00019.Loose Screws on the Braking Disk............................01/30/86 FIB 00020.Intermttant Errors in Errorlog Status 80120000 - ECN to Logi02/06/86 FIB 00021.Mechanical.Wear of Motor Mount..............................02/06/86 FIB 00022.Adjustment Procedures Manual Available from Technical Librar02/11/86 FIB 00023.R/W Head Part Number Clarification T-80,83,303..............02/11/86 FIB 00024.Incorrect Backplanes & Error in Schematics..................03/20/86 FIB 00025.Upper Carriage Crash Bar Loosening..........................04/03/86 FIB 00026.Stuck Disc Packs............................................04/24/86 FIB 00027.T-303 Read Only Switch......................................06/12/86 FIB 00028.Can't Adjust Data Separator while using the Trident Tester..08/26/86 FIB 00029.Motor Start-Capacitor Failure Symptoms & Correction.........02/19/87 FIB 00030.SUPERFLEX WIRE AVAILABLE FOR CARRIAGE GROUND LEAD REPAIR....07/14/87 FIB 00031.T20x/T30x BLOWER MOTOR CAPACITOR WIRE BREAKAGE..............09/22/87 FIB 00032.Manual Head Loading Dangers.................................03/07/88 FIB 00033.T303 Spindle Lockshaft Replacement..........................03/07/88 FIB 00034.Disk Pack Refurbishing & Formatting Procedure...............03/07/88 FIB 00035.P/N.FOR MULTI COAX FROM MATRICES TO DATA SEP PCB............04/15/88 FIB 00036.Head/Cylinder Errors on New/Rebuilt Packs...................08/30/88 FIB 00037.Servo Test Without Heads Installed..........................05/09/89 FIB 00038.Caution when carriage and ways need replacement.............05/22/89 FIB 00039.Disk Drive Blower Motor Failures due to 240V Strapping [ WPS03/05/90 FIB 00040.P/N for Disk Pack Threaded Shaft............................02/20/91 FIB 00041.Can't Enable Disk Error During Normal Type 1 Load...........03/27/91 FIB 00042.FAILURE TO LOAD HEADS AFTER SERVO HEAD REPLACEMENT..........04/21/93 DISK I/O-CALCOMP-T-303------------------------------Table Of Contents Pg01 of 01 FIB 00001 09/19/86 *** General Information *** The Calcomp T-303 (or model T300) is a 20 surface (19 data & 1 servo) removable media disk drive utilizing 14" media with a capacity of 312 MB unformatted (285 MB formatted). The T-303 is marketed by Basic Four as the model 4502 Removable Media Disk Drive for their 8000 & 9000 systems. Physical characteristics: Height 36 inches Width 19.5 inches Depth 33 inches Weight (shipping) 525 pounds Weight (operating) 480 pounds Power requirements: Input voltage - 208V or 240V single phase, jumper selectable Receptacle required - Nema 6-15R IG, Isolated Ground Starting current - 25 amperes rms for 10 seconds (nominal) Running current - 5 amperes (nominal) Circuit breaker required - 15 amperes Operating environment: Temperature - 60 to 90 degrees F (max rate of change 15 degrees F change per hour) Relative humidity - 10% to 80% (no condensation) Note: This range is too great for the rest of the system Heat dissipation - 3500 Btu/hour/drive *** Sorbus Machine Types and Feature Numbers *** Basic Four model 4502 Removable Media Disk Drive Sorbus type - 4308 *** Available Documentation *** Basic Four Model 4502 Removable Media Disk Service Manual (2 vol set) S-HDBK-B33 T-303 Disk Drive Adjustment Procedures................................S-HDBK-T35 T-303.Drive Carriage & Way Alignment Procedures.......................S-HDBK-T36 *** Available Training *** Included in the Basic Four 7000/8000/9000 course at both education centers. *** 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 DISK I/O-CALCOMP-T-303------------------------------FIB001 Pg001 Torque Wrench, Carriage/Way .................................MM249130/TQ5-6-FU Bit, Hex Key 3/32 (straight-tipped 1/4" drive)...............MM249195 Pack, Scratch ...............................................MM249200/907343-001 Fixture, Alignment Carriage/Way .............................MM249210/17585-001 Tool, Head Support ..........................................MM249220/10076-001 Exercisor, Sorbus Manufactured ..............................0R997565 Alignment Pack (also used on IBM 3330 Mod II drives).........KK004220 Tool, head alignment meter ..................................0R998441/17335-001 *** Special Administrative Procedures *** None required. ORIGINATOR: N. Jones DISK I/O-CALCOMP-T-303------------------------------FIB001 Pg002 FIB 00002 10/12/82 *** New Drive Motor Pulley Eliminates Belt Jumping Off *** Original Document Name - Mini Alert 74 SUBJECT: Trident Disc Drive Belt Slippage BFISD Model 4500, Sorbus Model 4283, 4303 Model 4500 Removable Media Disc Drives of recent manufacture may utilize a new spindle motor manufactured by Robbins & Meyers. These motors have an inordinate amount of starting and stopping torque. This increased torque on the motor pulley surface has been found to be responsible for belts that have slipped off during braking cycles. Revision 'E' changes to the physical dimensions of the pulley surface, has changed the crown and has eliminated the problem of belts slipping off with the use of the higher torque motors made by Robbins & Meyers. If you are experiencing belts slipping off or have replaced a spindle motor and are experiencing belt alignment problems, check the manufacturer of the spindle motor. If it is a Robbins & Meyers motor, Revision 'E' pulley, P/N 24362-001, MM 244570 (60HZ) or P/N 24362-002, MM 244910 (50HZ), should be installed to alleviate the problem. ORIGINATOR: J. Rippl DISK I/O-CALCOMP-T-303------------------------------FIB002 Pg001 FIB 00003 03/21/83 *** Preliminary Installation Instructions *** Original Document Name - Mini Alert 129 SUBJECT: System 810, Installation of 300MB removable disk T-303 BFISD model 4502 GENERAL: 1) The Model 4502 disk may be connected as the only drive on a TDP or it may be daisy chained with either a fixed media (P66, P154) or another removable disk (T-83, T-303). 2) The Model 4502 disk requires 208/240 volts (at 25 amps. surge). Electrical connection is by way of a NEMA 6-15P connector (6-15R Isolated Ground receptacle required). REQUIRED ITEMS: 1) Model 4502 disk drive 2) Bus cable Drive to Drive: 20 foot, BFISD P/N 906608-003 Standard: 35 foot, BFISD P/N 906608-006 Optional: 60 foot, BFISD P/N 906608-007 3) Radial Cable Standard: 35 foot, BFISD P/N 907111-003 Optional: 60 foot, BFISD P/N 907111-004 4) Sequence cable Drive to Drive: 20 foot, BFISD P/N 907140-001 Standard: 35 foot, BFISD P/N 907140-002 Optional: 60 foot, BFISD P/N 907140-003 5) Terminator, part of item 1. SWITCH SETTINGS: 1) Unit address on Model 4502 must be set to correspond to the TDP port being used (0* or 1*). This is done by setting switch module S2 on interface PCB ('GL66' card in slot 01 D/D, lower left of card cage). Settings: S 2-4 S 2-3 S 2-2 S 2-1 ADDRESS N/A OFF OFF OFF 0 * N/A OFF OFF ON 1 * N/A OFF ON OFF 2 N/A OFF ON ON 3 N/A ON OFF OFF 4 N/A ON OFF ON 5 N/A ON ON OFF 6 N/A ON ON ON 7 2) TDP Device Type: DISK I/O-CALCOMP-T-303------------------------------FIB003 Pg001 Set switch at location 2Z. Port 1 Port 0 7 6 5 3 2 1 OFF ON ON OFF ON ON NOTE: The correctness of these settings may be verified by using DEMON. 3) Degate Switch On-line position is UP, first artwork of interface PCB erroneously indicated UP as degated. 4) Chassis vs. Digital Ground Toggle switch to left of main power breaker (inside, behind card cage) should be in "ON-LINE" position to separate chassis ground from digital ground. DRIVE CABLING: 1) Cable Entry into the T-303 cabinet is on the bottom at the rear left corner. Once inside the cabinet, cables are routed between three (3) rubber retainers and side of cabinet. After passing the third retainer, cables cross over to the right and enter card cage area through a large grommet. Connections are as follows: Bus cable to J7 Radial cable to J8 Terminator to J6 Sequence in to J9 Sequence out to J10 Bus and radial cables are to be grounded inside the T-303 cabinet. At the rear left corner (near cable entry point) are two (2) bolts (these bolts are actually part of the attaching hardware for the caster), place cable ground lugs on these bolts and secure with 1/4" - 20 NC hex nuts. 2) When daisy chained to fixed media disk module. a. Fixed media drive to be first on bus daisy. b. Sequence in to removable disk is obtained from J2 on control panel of fixed media module. c. Bus and sequence cables to exit fixed media disk module through slot in rear cover. Bus cable should be secured and grounded with cable clamp. See Figures 1 and 2. d. Radial cable to exit from mainframe via side cable guides. ADDITIONAL INFORMATION: Sectoring jumpers on Servo Control II PCB (card slot A/B 03, top center) are as follows: Location 1A Location 1B Pin 4 - Pin 11 Pin 3 - Pin 12 Pin 6 - Pin 9 Pin 5 - Pin 10 Pin 6 - Pin 9 ** VERIFY PROPER OPERATION OF T-303 BY RUNNING DEMON DISK I/O-CALCOMP-T-303------------------------------FIB003 Pg002 ORIGINATOR: I. Leibowitz DISK I/O-CALCOMP-T-303------------------------------FIB003 Pg003 FIB 00004 05/26/83 *** ECN to Upgrade the I/O PCBA from REV. B to REV. C *** Original Document Name - Mini Alert 142A SUBJECT: T-303 TRIDENT I/O PCBA ENGINEERING CHANGE Century Data has released an engineering change to the T-303 I/O 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. This change is MANDATORY on the next service call or PM (See Mini Management Bulletin #9). This MINI-SYSTEMS ALERT gives all information necessary to update and identify the PCBA, however you may also elect to order . the updated part from NACS Materials, specifying the revision level required. Following are PCBA identification and rework instructions: PART NUMBER REVISION LEVEL Manufacturer/Sorbus Description Old New 24086-001/MM246030 I/O PCBA (T-303) /B /C REWORK INSTRUCTIONS 1) Cut etch on solder-side at IC 3D pin 04. 2) Add 30 ga. insulated wire on component side from IC 2D pin 10 to 3D pin 04. 3) Change PCBA Revision marking to 24086-001/C 4) Record your time as Service Code 09 ORIGINATOR: J. Kanzler DISK I/O-CALCOMP-T-303------------------------------FIB004 Pg001 FIB 00005 09/23/83 *** Information on Securing the Cable Grounding Straps *** Original Document Name - Mini Alert 191 SUBJECT: T-303 INSTALLATION CABLE GROUNDING BFISD MODEL 4502, NACS TYPE 4308 During Installation of the T-303 Removable Disk Drive the cable grounding lug may be too short to properly attach the cable grounding straps, especially on multiple drive systems. Since it is impractical for this bolt to be replaced in the factory, disk units will be shipped (after 9/16/83) with a package containing a longer bolt to allow proper cable grounding. TO ENSURE PROPER DISK-TO-SYSTEM GROUNDING, THE SHORT BOLT MUST BE REPLACED WITH THE ENCLOSED LONGER BOLT ON ALL T-303 DISK DRIVES DURING INSTALLATION ON SITE. REF: ECN 8950 ORIGINATOR: J. Rippl DISK I/O-CALCOMP-T-303------------------------------FIB005 Pg001 FIB 00006 11/03/83 *** Read/Write Head Alignment Using Demon *** Original Document Name - Mini Alert 139 & 139S NOTE: If at all possible head alignment should not be attempted without an exercisor preferably the Sorbus manufactured exercisor P/N 0R997565. General: 1. This procedure is intended to alleviate the problems encountered with the original procedure. 2. This procedure does not require shorting IC pins to select heads, but it does require that the drive NOT be degated (target drive must remain "on-line"). 3. The DEMON set up procedure is also appropriate for te T-83. Equipment Set Up: 1. Connect T2001A alignment meter to top connector J01 on the Read Limiter PCB (card slot 5A/B, top right of card cage). 2. Three test points are provided on the Read Limiter PCB for an oscilloscope. a. Channel 1 should connect to test point E01 (very top of read limiter PCB above J01). b. Channel 2 should connect to test point E03 (directly below J01). c. Probe grounds should be attached to test point E02 (above J01, just below E01). d. Sync on channel 1 (internal), invert channel 2, and select ADD mode. e. Both vertical amplifiers must be set for the same volts/div. A setting of 50 mv/div. (using X10 probes) gives a good display. DEMON Set Up: * Alignment pack should be installed and heads loaded at this point. After obtaining the DISK TEST menu, enter a "Z" to set all test options for "O" iterations and proceed as follows (see attached examples): 1. Select test option 5 (Read Tracks) and set for one iteration. 2. A sub-menu should now have appeared on the screen, set the five options as follows: a. Start cylinder: 496 b. End Cylinder: 496 c. Step (#,R): 1 d. Start head: N N = the number of the head to be aligned. e. End head: N 3. Upon return to the DISK TEST menu, enter a "B" so that "Loop on Error" becomes "Y". 4. Enter a carriage return, then enter "R" to run. Note: (1) Once the disk test executes, do not make any keyboard entries. (2) Do not "degate" the drive to be aligned. 5. A software time-out should occur (after about 25 seconds) and the carriage DISK I/O-CALCOMP-T-303------------------------------FIB006 Pg001 should remain at cylinder 496, insert the safety ("grenade") pin. If drive re-zeros, verify correct set up of the menus. 6. The selected head may now be aligned. 7. To select another head for alignment proceed as follows: a. Remove the safety pin. b. Use MBIV to return to the selector. The drive's carriage should still be at 496. c. It will be necessary to Quit the test, and re-select the test in order to select another head. See attached "photos", note the items with an "*" contained in Mini Alert 139S. ORIGINATOR: I. Leibowitz DISK I/O-CALCOMP-T-303------------------------------FIB006 Pg002 FIB 00007 01/23/84 *** Miscellaneous Drive Failures due to Board Seating Problems *** Original Document Name - Mini Alert 220 Many T-303 drives have extremely loose fitting board sockets due to card cage mis-alignment. Some card cages were pop riveted and cannot be adjusted but most have card guides held by screws in slotted holes allowing adjustment. Adjust as follows: 1. Loosen both ends of the cage. 2. Insert a PCB (PROPERLY SEATED) in each end of the backplane. 3. Adjust the card guides parallel to the PCBs, with .015" to .020" clearance to the PCBs at both ends. CAUTION: DO NOT OVERTIGHTEN THE SREWS THEY STRIP EASILY! ORIGINATOR: D. Loiselle DISK I/O-CALCOMP-T-303------------------------------FIB007 Pg001 FIB 00008 02/28/84 *** Logic I Below LARL can Cause R/W Errors with Status of HEX 81000000 *** Original Document Name - Mini Alert 231 SUBJECT: T83/T303 Disk Errors If diagnostics or the error log show that a T83 or T303 is having recoverable read or write errors with a hex status of "81000000". ID sync error, check the revsion level of the logic I board. Model PCBA P/N MM No. LARL T83 24050-001 245000 D T303 16407-001 246040 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. T83 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. T303 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: Seee Mini Alert 231 hardcopy for drawing. ORIGINATOR: J. Kanzler DISK I/O-CALCOMP-T-303------------------------------FIB008 Pg001 FIB 00009 05/15/85 *** Lowest Acceptable Revision List (LARL) *** Original Document Name - Mini Alert 359A At the next service call check the revision level of each part listed below. Replace all parts below the LARL. This service call is not billable, therefore use Service Code 17 or 22. Do not write the part up on the IR; indicate on the DMT as Revision Upgrade. MM# Vendor P/N Description LARL MM245030 24102-001 PCBA, TERMINATOR A MM246010 16627-001 PCBA, DATA SEPARATOR T MM246020 13794-001 PCBA, EMERGENCY RETRACT G MM246030 24086-001 PCBA, INTERFACE C MM246040 16407-001 PCBA, LOGIC CONTROL I D MM246050 16687-001 PCBA, LOGIC CONTROL II H MM246055 26529-001 PCBA, LOGIC II LID-LOCK F MM246060 23616-001 PCBA, OPTICAL E MM246070 16458-001 PCBA, READ LIMITER P MM246080 19842-001 PCBA, R/W MATRIX LEFT E MM246090 19845-001 PCBA, R/W MATRIX RIGHT A MM246100 16470-001 PCBA, SERVO CONTROL I S MM246110 16461-001 PCBA, SERVO CONTROL II H MM246120 19040-001 PCBA, SERVO HD PREAMP E MM246140 16366-001 POWER AMP ASM E MM246150 16360-001 POWER SUPPLY ASM, 60HZ G Check your field stock and return all parts below LARL to Sorbus Materials West. The drives must be at LARL to perform reliably. ORIGINATOR: E. Unten DISK I/O-CALCOMP-T-303------------------------------FIB009 Pg001 FIB 00010 05/15/85 *** Read/Write Clock Frequency Adjustment Procedure *** Original Document Name - Mini Alert 358 SUBJECT: R/W CLOCK FREQUENCY ADJUSTMENT (POSSIBLE CURE FOR IMAGE BACKUP PROBLEMS ON THE SYSTEM 8000) NOTE: There is a handbook available which covers all drive electronic adjustments - T-303 Drive Adjustment Procedures S-HDBK-T35. There seems to be some confusion about the adjustment procedure of 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-303------------------------------FIB010 Pg001 FIB 00011 06/17/85 *** A/C Input Voltage Tap Setting *** Original Document Name - Mini Alert 371 The Trident T-303 Removable Disk Drive power supply primary winding contains taps that can be selected for input voltages of 208 or 230 volts. The manufacturer ships these units set at 208 volts and Basic Four changes the setting to 230 volts. There have been some cases where the tap was set to 208 volts and the source voltage was 230 volts. Transformer heat increased to the point that an odor could be detected. At installation time, the source AC voltage should be measured and the drive set to the proper tap, as follows: Locate P-33 on the AC Distribution box. Opposite end of P-33 is P-14 that plugs into the power supply. There are three wires in P-14; green, black and white. Connect the white wire to pin 1 for 230 volts, or to pin 2 for 208 volts. (See figure 2-2 on page 2-5 of the Service Manual). Use pin extractor MM629020. NOTE: Installed units should be checked as soon as possible. ORIGINATOR: J. Buscaglia DISK I/O-CALCOMP-T-303------------------------------FIB011 Pg001 FIB 00012 07/02/85 *** Annual Preventive Maintenance Schedule *** Original Document Name - Mini Alert 367B PREVENTIVE MAINTENANCE SCHEDULE FOR T-303 DISK DRIVE 60 DAY MAINTENANCE SCHEDULE ------------------------------------------------------------------------------- COMPONENT PROCEDURE REMARKS ------------------------------------------------------------------------------- External Cabinet surfaces Clean Soft cloth and mild detergent Read/Write heads Inspect Refer to manual Paragraph 4.4.1.1 Air Shroud Clean Refer to manual Paragraph 4.2.2.2 Spindle surface/threads Inspect/Clean Refer to manual Paragraph 4.2.2.4 Spindle drive belt Inspect Refer to manual Paragraph 4.5.3.2 Intake air filter Clean Refer to manual Paragraph 4.2.2.5 Air system boot Inspect/Replace See *Note 6 MONTH MAINTENANCE SCHEDULE ------------------------------------------------------------------------------- COMPONENT PROCEDURE REMARKS ------------------------------------------------------------------------------- Perform all 60 day Preventive Maintenance Schedule Internal Cabinet surfaces Clean Use a soft brush and vacuum Carriage and way system Inspect/Clean Refer to manual Paragraph 4.2.2.3 Spindle grounding brush Check Resistance Refer to manual Paragraph 4.5.3.1 Power Supply Check voltages Refer to manual Section II Read/Write system Check alignment Refer to manual Paragraph 4.5.1 Positioning system Check adjustment Refer to manual Paragraph 4.5.2 Spindle drive system Check operation Refer to manual Paragraph 4.5.3 Air system boot Inspect/Replace See *Note Motor mount bushing Replace See *** *** Part numbers are: MM246385 Bushing, motor (2 of each needed) MM246386 Washer, flat (Nylon) The above 60 day and 6 month Preventive Maintenance schedules are listed in the Service Manual. The Annual Preventive Maintenance schedule was inadvertently left out. In this document we list the complete Preventive Maintenance schedule. ANNUAL MAINTENANCE SCHEDULE ------------------------------------------------------------------------------- COMPONENT PROCEDURE REMARKS ------------------------------------------------------------------------------- Perform 60 Day Preventive Maintenance Schedule Perform 6 Month Preventive Maintenance Schedule Absolute Air Filter MUST REPLACE Refer to manual Paragraph 5.2.2 Air system boot Inspect/Replace See *Note Lid gasket Inspect/Replace See *Note * Note: If the disk drive is operating in a high ozone environment, the air system boot inspection procedure should be included in the 60 day inspection cycle. In areas of normal or low ozone environment levels, the inspection procedure should be performed during the 6 month and/or annual Preventive Maintenance cycle. Note I The alignment pack should be allowed to stabilize at the customer site for at least 2 hours prior to the alignment check and should be run in DISK I/O-CALCOMP-T-303------------------------------FIB012 Pg001 the drive for at least 15 minutes. Note II After servo adjustments are performed, head alignment should be verified. Note III Do not subject the alignment pack to environmental extremes, (hot or cold), or shock. The pack may be permanently damaged. Note IV Test equipment and torque wrenches should be checked for calibration at least once a year, or sooner in cases of hard use. ORIGINATOR: J. Buscaglia DISK I/O-CALCOMP-T-303------------------------------FIB012 Pg002 FIB 00013 08/15/85 *** R/W Head Mounting Screw Torque Change & New Torque Wrench *** Original Document Names - Mini Alerts 172 & 405 The torque specification for head mounting screws on all TRIDENT drives (T80, T83, & T303) has been changed to 104 inch-ounces. Please change all documentation to reflect this change. TOOLS REQUIRED FOR LOCKING DOWN R/W HEADS 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 T80, T83, T303 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) NOTE: When any wrench or screwdriver utilizing an adjustable pre-load spring is stored, the torque adjustment should be set to its lowest setting to prevent premature loss of calibration. ORIGINATOR: C. Gahan DISK I/O-CALCOMP-T-303------------------------------FIB013 Pg001 FIB 00014 08/27/85 *** Check Input Transformer before Replacing the Power Supply *** Original Document Name - Mini Alert 407 95% of the T-303 power supplies returned from the field for repair, have been found to have a burned transformer primary winding. When a defective power supply is suspected, check the transformer, and if an open winding is found, only the transformer should be replaced. The defective transformer may be discarded locally. Order - MM246155 Vendor # 13111-060 Transformer 60cy. NOTE: Probable cause of burning primary winding is wrong transformer tap selection. See FIB in this group titled 'A/C Input Voltage Tap Setting'. for voltage strapping information. ORIGINATOR: J. Buscaglia DISK I/O-CALCOMP-T-303------------------------------FIB014 Pg001 FIB 00015 10/22/85 *** Service Hints for -50 Volts DC Problems *** Original Document Name - Mini Alert 418 The voltages named "+50V" and "-50V" are unregulated and will nominally measure about + or -38V. DC. These voltages are rectified and filtered on the Power Amplifier Board, and are used primarily to drive the servo motor. They are also used for the brake magnet, in the head selecting circuits, in the logic and to develop read/write currents. Where the voltages are being applied is not entirely clear on the logic drawings that are being used in the field. The Right Read/Write Matrix Board has a regulation circuit that uses "-50V" for a source to regulate a -24V. which is then used in its own heads select circuits and fed to the Left Read/Write Matrix Board for the remaining heads select circuits. Do not overlook either Read/Write Matrix board as a cause if the "-50V" is being overloaded. Disconnecting J2 on the main card cage (upper right corner viewed from the rear) will isolate both Matrix Boards; disconnecting J3 will isolate the left board only. Disconnecting J1 on either board will also isolate that individual board. Be aware that a "-50V" fault could also damage components on either Matrix Board. ORIGINATOR: C. Gahan DISK I/O-CALCOMP-T-303------------------------------FIB015 Pg001 FIB 00016 05/04/88 *** POTENTIAL A/C VOLTAGE SHORT TO FRAME MISC.READ ERRORS *** Original Document Name - Mini Alert 429 (modified) The leads to the blower motor cap (mounted on the blower motor) are too long and touch the frame. Due to vibration they will wear and short AC to frame. This has occurred in at least one location with catastrophic consequences. Misceleaneous errors ,including intermittent read errors have occured due to intermittent arcing of these wires. ALL T-303 DRIVES SHOULD BE CHECKED FOR THIS CONDITION ON THE NEXT PM. The solution is to tie the AC wiring to the blower motor as follows: 1. Remove absolute filter, disconnect P/J32 at the AC distribution box, remove any cable tie downs on the blower wiring harness, remove the 8 hex head screws holding the blower housing to the plenum, and remove the blower housing with motor. Using electrical tape repair any insulation damage to the wiring. 2. Wrap a cable tie around the blower motor as a tie down point for the wiring, this will probably require linking two ties together, and leave loose for the moment. 3. Using a small cable tie, tie the wiring to the cable tie around the motor. Position the tie point in the center of the AC wiring harness. 4. Pull the cable tie around the blower motor tight, it should be near the center of the motor. This will provide a secure tie-down for the loose wiring harness. 5. Install blower housing onto the plenum taking care to place the rubber grommet on the AC harness in the groove. ORIGINATOR: B. Berard DISK I/O-CALCOMP-T-303------------------------------FIB016 Pg001 FIB 00017 12/11/85 *** Information and Procedure on R/W Heads with Defective Cables *** Original Document Name - Mini Alert 427 In August of this year, read/write head manufacturers admitted there had been a period of time during which they had been supplying heads to Century Data Systems that the cabling to the heads was of a more brittle nature than that used in original production. The inferior wire used started to cause problems first noticed in the fall of 1984, and was not recognized as a trend for a considerable amount of time. The insulation and/or the wire would crack about 1/4 to 1/2 inch beyond the shrink- tubing at the connector end of the coiled spring. The failure usually indicates intermittently open head coils, and first shows up as soft read errors in the data field records. As the majority of removable disc drives installed during late '84 and early '85 were T303s, the problems have appeared to be confined to that type drive; in fact, this is not entirely the case. T80s and T83s may also have problems, as they use the same type of heads. Most of the failing heads may be observed with a scope when set up to make head alignment adjustments. The head in question may lose its read signal if the cable is flexed or stressed, although this will not always induce a failure. If the cable insulation has cracked and the center-tap wire shorts to the coiled spring that encases the wires, a failing head may work OK when it is selected, but affect other heads connected to the same Read/Write Matrix Bd. when they are selected, causing the good heads to exhibit errors. The logistics of correcting the problem are going to be painful. It will be up to the judgement of the field to determine the need for obtaining the new heads according to the customer situation and the severity of the failures at the given moment. Shipments of R/W heads with stronger wires in their cables are now starting to come into the Parts Center. The first shipment of new heads had orange shrink-tubing around the coiled spring holding the wires. The most recent has blue shrink-tubing, with a clear plastic round sticker on the connector marked "IV 85". The marking is difficult to read on the black connectors, but quite visible on the lighter colored connectors. Ideally, replacing all twenty heads at one time on a problem drive would appear to be the way to approach the situation. However, the problem of the demand exceeding the supply will soon be felt, if it hasn't been already. At this time, Century Data has offered warranty replacement for some of the heads with frayed wires. The CDS disc drive serial number must be indicated for each individual head replaced to obtain the warranty replacement. It will be very important for the field to keep track of the heads that are replaced to prevent duplicate replacement. Logistics has a list of critical customers that was prepared by the local District Product Specialists. The heads for the machines at these customers will be filled automatically on a Code C, and shipped to the appropriate office with attention to the DPSS, as soon as they become available. Use the normal DISK I/O-CALCOMP-T-303------------------------------FIB017 Pg001 ordering procedures to obtain emergency spare heads. DO NOT order 20 heads on a Code A. Insure that all heads returned have the Century Data serial number of the drive marked on the DMT. Indicate heads used on the IR. This is not billable, and therefore Service Code 17 or 22 must be used. It is the DPSS's responsibility to keep track of the number of drives and the time spent to replace these heads to get compensation for the cost of the retrofit. This must be done by sending copies of the IRs to Ernie Unten, Planning and System Support. ORIGINATOR: C. Gahan DISK I/O-CALCOMP-T-303------------------------------FIB017 Pg002 FIB 00018 12/18/85 *** Braces Available for R/W Head Cables to Reduce Vibration & Static *** Original Document Name - Mini Alert 422A Century Data Systems has made available braces to support the cables to the Read/Write heads. These braces act as a substitute for the cable guide combs used on the T80 drive, and are added to reduce cable vibration and static electricity buildup caused by the motion of the carriage. This is NOT intended to cure head cable wire breakage. That problem will be addressed in a future Mini-Alert. The kit for the braces, YY016795, will contain a pictorial diagram on where and how to install them. The kits are in stock, and should be ordered only as Code B items. They are easily installed, but insure that the braces do not interfere with carriage motion. Visually observe that the carriage will fully retract during a "power off" and will perform full-track seeks without restriction. The kits are to be installed on a scheduled PM, and will not be billable. As both Century Data and Basic Four wish to track the machine performance of the disk drives, insure that the installation date of the braces is noted in the site log. ORIGINATOR: C. Gahan DISK I/O-CALCOMP-T-303------------------------------FIB018 Pg001 FIB 00019 01/30/86 *** Loose Screws on the Braking Disk *** Original Document Name - Mini Alert 442A It appears that the retaining screws which hold the metallic braking disc to the spindle are working themselves loose. Please check these screws on a PM call or the next service call. In one account we found two out of three T303 disk drives had screws missing or loose. If left unchecked this could cause damage to the speed sensor and severe damage to other parts of the drive. NOTE: Please see drawing Figure 6-2, page 6-12 in Vol II of the T-303 Service Manual, Item 148 DRAWING INFORMATION: See drawing in mini alert #442A hardcopy. ORIGINATOR: A. Mollyhorn DISK I/O-CALCOMP-T-303------------------------------FIB019 Pg001 FIB 00020 02/06/86 *** Intermttant Errors in Errorlog Status 80120000 - ECN to Logic II *** Original Document - Mini Alert 453 Century Data has released a field change notice correcting a problem on Logic control II ICN MM246055. The problem causes the ready timer to start 1 to 2 msec. too early when completing a seek. This may show up as soft errors if the failure occurs during a read operation , and device checks during a write operation. The failures are likely to be highly intermittent. Logic control II modified PCBA is REV "F". ORIGINATOR: Chuck Gahan DISK I/O-CALCOMP-T-303------------------------------FIB020 Pg001 FIB 00021 02/06/86 *** Mechanical Wear of Motor Mount *** Original Document Name - Mini Alert 451 Premature wear of motor mounting plate assembly evidenced by a red dust coating on the interior of the drive. Carefuly clean the drive interior (don't overlook the backplane) and replace the worn bushings/motor mount. Parts Involved MM246385 Bushing (2 required) MM246386 Washer (2 required) MM246740 Motor Mounting Plate (1 required) 0R998905 Molykote G - Use light coat on motor mounting plate. Refer to the FIB in this group titled 'Annual Preventive Maintenance Schedule' for PM scheduling. ORIGINATOR: C. Gahan DISK I/O-CALCOMP-T-303------------------------------FIB021 Pg001 FIB 00022 02/11/86 *** Adjustment Procedures Manual Available from Technical Library *** Original Document Name - Mini Alert 412A The T-303 Adjustment Procedures booklet is now available from the Technical Library. Order Manual T-35. The adjustments of T-303's are extremely critical. Those described in the manual should be closely adhered to and the tolerances given must be observed. ORIGINATOR: J. Buscaglia DISK I/O-CALCOMP-T-303------------------------------FIB022 Pg001 FIB 00023 02/11/86 *** R/W Head Part Number Clarification T-80,83,303 *** Original Document Name - Mini Alerts 381B & 474 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. In addition heads have been purchased from several sources with different markings. The following list should help identify the R/W 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 2 MM240360 13502-001 331137-502 Servo Hd ORIGINATOR: Buscaglia/Gahan DISK I/O-CALCOMP-T-303------------------------------FIB023 Pg001 FIB 00024 03/20/86 *** Incorrect Backplanes & Error in Schematics *** Original Document Name - Mini Alert - 464 There has been at least one recent shipment of a backplane for a T303, ICN MM246375 that turned out to be an incorrect Century Data P/N and was not wired for Lid-Lock. The P/N for the incorrect part was 24081-001; the Lid-Lock version is P/N 24081-002. The Lid-Lock version will work in a machine that does not have the feature. Check all field stock and drives for the incorrect backplane and replace as necessary. This also brought out that there is an error in the documentation in the Lid- Lock circuit on the logic diagram for Logic Control II PCB, Figure 7-25, page 7-29 of the Service Manual, BFISD 8073P, Vol. II. The wiring to J/P 04, pin 02 (to the Lid-Lock Solenoid) comes from A/B 04, pin B54 (not pin A19 as indicated) Another error is in the latest Parts Matrix. There the part is listed as MM246370, which IS Century Data P/N 24081-001. This version is missing the wire wrapped from J04, pin 02 to A/B 04, pin B54. ORIGINATOR: C. Gahan DISK I/O-CALCOMP-T-303------------------------------FIB024 Pg001 FIB 00025 04/03/86 *** Upper Carriage Crash Bar Loosening *** Original Document Name - Mini Alert 473 The crash bar centered above the carriage on the T-303 can become loose at either end or shift position causing the "t block" to bind in a manner that would appear to be a bad carriage bearing. ORIGINATOR: Mike Pepper DISK I/O-CALCOMP-T-303------------------------------FIB025 Pg001 FIB 00026 04/24/86 *** Stuck Disc Packs *** Original Document Mini Alert 477 There have been occasions when packs have appeared as stuck to the spindle of T-303, drives and the cover cannot be used to remove them. This is caused by the user not turning the cover completely clockwise when the pack is mounted. This causes three spindle balls in the shaft to not completely retract and prevents the cover from re-attaching to the pack. To correct this a sturdy pair of long nose pliers can be used to turn the spindle on the pack until there is no movement, which will allow the cover to be used to remove the pack. ORIGINATOR: TIC DISK I/O-CALCOMP-T-303------------------------------FIB026 Pg001 FIB 00027 06/12/86 *** T-303 Read Only Switch *** The T303 read only switch will not change the status of the drive (R/W or READ . ONLY) while the pack is spinning. The switch is operational under certain selection conditions, but it is unconditionally operational when the pack is not spinning. If it is necessary to change from READ/WRITE to READ ONLY or vice versa, turn the ON/OFF switch to OFF, set the READ WRITE/ READ ONLY switch to the desired position and turn the ON/OFF switch to on. ORIGINATOR: Jaime Buscaglia DISK I/O-CALCOMP-T-303------------------------------FIB027 Pg001 FIB 00028 08/26/86 *** Can't Adjust Data Separator while using the Trident Tester *** Original Document Name - Mini Alert 493 When performing data separator adjustments the trident disk exerciser should be removed. Failure to do this will make the scope display very fuzzy and cause the adjustments to be hard or impossible to do correctly. ORIGINATOR: Harvey Mitchell DISK I/O-CALCOMP-T-303------------------------------FIB028 Pg001 FIB 00029 02/19/87 *** Motor Start-Capacitor Failure Symptoms & Correction *** SYMPTOM: Motor Overheats on Spinup or Fails to Reach Full Speed PROBLEM DETERMINATION: Eddy-current Brake working properly (no braking when. motor energized) but motor torque too low to reach synchronous speed in time. May show signs of leakage from capacitor housing on motor. FIX: Test the motor for no-load spin-up by removing the drive belt. This also allows listening for noisy bearings. If the motor appears to work properly with no load, replace the start-capacitor and re-test under load. The capacitor has caused approximately 50% of the motor failures observed recently at NACS WEST. The motor need not be removed to replace the capacitor. ENSURE THAT THE DRIVE CIRCUIT BREAKER IS OFF BEFORE REMOVING THE CAPACITOR HOUSING. CAREFULLY PRY THE CAPACITOR OUT OF THE HOUSING AND UNPLUG THE LEADS. THE LEADS ARE NOT POLARIZED AND CAN BE PLUGGED ON EITHER TERMINAL. INSTALL THE NEW CAPACITOR IN EXACTLY THE SAME POSITION SO THAT IT CANNOT SLIDE AGAINST THE END OF THE HOUSING. There are at least two types of spindle-drive motors used on T200/300 . and T303 drives. The capacitors can usually be purchased locally, and may also be ordered from NACS WEST using the NACS ICNS as follow: MOTOR MFR. CAP. DIMENSIONS SPECIFICATIONS NACS ICN ---------------- --------------- ----------------- ---------- GOULD/CENTURY 1 7/8 X 3 3/8" 108-130MFD 220VAC YY018283 GENERAL ELECTRIC 2 1/16 X 4 3/8" 108-130MFD 330VAC YY018281 MANUFACTURED BY MALLORY OR MEPCO/ELECTRA & OTHERS NOTE!!! DO NOT SUBSTITUTE --- DO NOT ORDER CAPACITORS 'CODE A' IF AVAILABLE LOCALLY (TRY W.W. GRAINGER) THE PURCHASE PRICE WILL BE $5 TO $10. ALSO AVAILABLE FROM MOTOR SHOPS, ELECTRIC SUPPLY HOUSES, AND SWIMMING POOL SUPPLY DEALERS. NOT USUALLY FOUND AT ELECTRONIC DISTRIBUTORS. IF YOU HAVE A MACHINE DOWN AND NO LOCAL STOCK OF THE NACS PART, BUY CAPACITOR LOCALLY AND/OR ORDER THE MOTOR AS REQUIRED. ORIGINATOR: J. Vander Heyden DISK I/O-CALCOMP-T-303------------------------------FIB029 Pg001 FIB 00030 07/14/87 *** SUPERFLEX WIRE AVAILABLE FOR CARRIAGE GROUND LEAD REPAIR *** SYMPTOM: Carriage ground wires broken (may cause severe damage if shorted to voltages on Read-Matrix PCBAs) PROBLEM DETERMINATION: Visual inspection (investigation of Read/Write errors) FIX: Repair the carriage ground wires using 'SUPERFLEX' wire available from NACS WEST MATERIALS. Re-use the special terminal lugs attached to the carriage and replace the ring terminals used for the frame-ground ends of the wires with locally-purchased terminals. The accepted method of strain-relief is RTV silicon adhesive at the ring-terminals and heat- shrink tubing at the carriage-terminals. CAUTION! DO NOT USE ANY OTHER TYPE OF WIRE FOR THIS APPLICATION AND ENSURE THAT THE STRAIN-RELIEF IS DONE CORRECTLY. THE POTENTIAL DAMAGE FROM A VOLTAGE SHORT-TO-GROUND IS VERY SEVERE. NACS ICN DESCRIPTION UNIT OF MEASURE ---------- ------------------------- --------------- YY018713 Wire, SUPERFLEX insulated FEET The specified lengths of wire for each ground lead are 5.1 inches for the longer lead and 4.4 inches for the shorter lead, resulting in lengths of 6.5 and 5.8 inches from lug-hole center to center. The ring terminal sizes specified are #4 (shorter wire) and #10 (longer wire). The ring terminals are to be soldered to the wires and filled with RTV to strain- relieve the insulation rather than crimped. ORIGINATOR: J. VanderHeyden DISK I/O-CALCOMP-T-303------------------------------FIB030 Pg001 FIB 00031 09/22/87 *** T20x/T30x BLOWER MOTOR CAPACITOR WIRE BREAKAGE *** SYMPTOM: Blower motor fails to start or runs slow due to broken wires at the capacitor terminals. FIX: See FIB 4308-16 for preferred method of repair. Strip and re-solder the broken wires if necessary. This problem is caused by vibration and may cause disastrous results. On 6/2/87, CENTURY DATA began tying the capacitor leads to the capacitor, to prevent the service- loop from flexing at the solder joint. NOTE: The wires can be broken inside the insulation if the protective insulator is acting as a strain-relief. Securing the Blower Motor wiring per FIB 4308-16 should be done at the next opportunity. ORIGINATOR: J. VanderHeyden DISK I/O-CALCOMP-T-303------------------------------FIB031 Pg001 FIB 00032 03/07/88 *** Manual Head Loading Dangers *** CENTURY DATA SYSTEMS strongly recommends against loading the heads manually on any TRIDENT series disk drive. They report that the heads may crash if the speed of forward motion is not the same as a servo-controlled load (3 in./sec). This also applies to unloading. The heads are very sensitive to rate of travel when engaging or disengaging the ramps on the cam tower. Any procedures which previously specified manual head-loading should all be changed to require normal power-on servo-controlled load. If the carriage must be manually moved after loading, this can be accomplished by placing the Servo Disable switch (Logic II, 4A/B) in the "DISABLE" position. Be Sure to place this switch back to the "ENABLE" position before sequencing the drive down so that the heads will retract normally. ORIGINATOR: J. VanderHeyden DISK I/O-CALCOMP-T-303------------------------------FIB032 Pg001 FIB 00033 03/07/88 *** T303 Spindle Lockshaft Replacement *** SYMPTOM: Stripped threads in the spindle lockshaft (pack won't lock ON) FIX: Replace only the Spindle Lockshaft. Lockshafts are now available from N.A.C.S. Materials (Tustin). The part number and procedure are shown below. Previously, entire spindle assemblies had to be replaced for this condition, requiring complete alignment. Lockshaft replacement can be accomplished in approximately 15 minutes and requires no alignment. Replacement of the Lockshaft is performed as follows: SPECIAL TOOL(S) REQUIRED: Internal retaining-ring pliers (may be obtained at most Auto Parts Dealers) 1. Remove the pack (if installed). Leave the lid open and remove power from the drive. 2. Remove the front and right side covers, absolute filter, and spindle ground brush. (Removal procedures in BFISD 8073 or CENTURY DATA SYSTEMS Trident Model 200/300 Maintenance Manual.) In order to support the right side of the absolute filter upper duct, hook the right-hand spring into the frame bracket on the right-front frame upright. 3. Support the lockshaft by holding the grounding button upward and remove the retaining-ring in the bottom center of the spindle. CAUTION: THERE IS SPRING TENSION (DOWN) AGAINST THE NYLON LOCKSHAFT RETAINER! 4. Allow the nylon retainer, spring, and lockshaft to drop out of the spindle. 5. Install the new lockshaft, rotating it to allow the flat sides near the top to seat into the matching keyed section of the spindle, then install the spring, nylon lockshaft retainer, and retaining-ring. 6. Ensure that a pack can be installed on the spindle, then remove it. 7. Reinstall the spindle ground brush, absolute filter, and covers before restoring power to the drive. 8. Test the drive befor returning it to the customer. Part Number Vendor Part Number Description ----------- ------------------- --------------------------------------- MM246225 27327-001 or 332130 Lockshaft, Spindle (large Trident) ORIGINATOR: J.VanderHeyden DISK I/O-CALCOMP-T-303------------------------------FIB033 Pg001 FIB 00034 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-303------------------------------FIB034 Pg001 FIB 00035 04/15/88 *** P/N FOR MULTI COAX FROM MATRICES TO DATA SEP PCB *** SYMPTOM/TEXT: THE P/N FOR THE MULTI COAX FROM R/W MATRICES TO THE DATA SEP. PCB CALCOMP P/N 17740-001 IS MM246610 FIX: IF YOU HAVE A DRIVE WRITING GARBAGE, THIS MAY BE THE PROBLEM. ORIGINATOR: PETE DOBROW 15DPS3 LOGON: 15DPS3 DISK I/O-CALCOMP-T-303------------------------------FIB035 Pg001 FIB 00036 08/30/88 *** Head/Cylinder Errors on New/Rebuilt Packs *** SYMPTOM: Intermittant head/cylinder errors may occur on new or rebuilt packs recently received from MBF. PROBLEM DETERMINATION: Use NEWX/DEMON/DCL to test the packs at a different location if possible. FIX: Replace the defective pack(s). NOTE: Replacement packs should be tested THOROUGHLY also (at another location if possible). The test procedures are due to be tightened up, but beware. ORIGINATOR: N. Jones/J. Rogers DISK I/O-CALCOMP-T-303------------------------------FIB036 Pg001 FIB 00037 05/09/89 *** Servo Test Without Heads Installed *** SYMPTOM/TEXT: When troubleshooting servo problems that could cause potential head crashes, the following procedure can be used: Remove all heads and spin up the Drive. If operating properly, after reaching load speed the Tower should move out slowly looking for servo then stop at end of travel and be free floating. This test proved useful to check servo on a Drive which had crashed all 20 heads due to a Servo problem. FIX: This information compliments of Jim Horst/John Hotze ORIGINATOR: Barry Matthews DISK I/O-CALCOMP-T-303------------------------------FIB037 Pg001 FIB 00038 05/22/89 *** Caution when carriage and ways need replacement *** SYMPTOM/TEXT: When the carriage way rail fatigues and begins to wear away, metal flakes and particles may be thrown up into the actuator motor magnet and voice coil assembly. This metal can cause damage to the voice coil and can adversely effect the magnetic fields within the actuator, causing seek errors and the drive to drop ready. FIX: Whenever the carriage and ways must be replaced, it is advisable to also do the following: 1. Remove the tach rod and tach coil assembly 2. Remove the actuator motor magnet 3. Clean and inspect the actuator coil asm. for damage 4. Clean and re-install the actuator motor magnet 5. Clean and re-install the tach coil and tach rod 6. Carefully clean the entire upper portion of the drive ORIGINATOR: H. Mitchell DISK I/O-CALCOMP-T-303------------------------------FIB038 Pg001 FIB 00039 03/05/90 *** Disk Drive 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-303------------------------------FIB039 Pg001 FIB 00040 02/20/91 *** P/N for Disk Pack Threaded Shaft *** SYMPTOM/TEXT:.Disk drive shaft threads get eaten up due to worn threads on the disk pack shaft. FIX: Inspect and replace all worn disk pack shafts MM246005, on both production and backup packs. At the same time inspect and replace, if necessary, worn spindle shafts in all the disk drives, MM246225. ORIGINATOR: John Tank DISK I/O-CALCOMP-T-303------------------------------FIB040 Pg001 FIB 00041 03/27/91 *** Can't Enable Disk Error During Normal Type 1 Load *** SYMPTOM/TEXT: Can't enable disk error during a type 1 load. This usually happens when a customer has a backup pack in the drive. This is caused by a hard disk error that occured during a backup operation. If the operator aborts or skips sectors during a backup, a flag is set on the disk to denote that the backup did not finish normally, so data on the pack is suspect. You can do nothing with the pack until YOU RESET THE FLAG!! FIX: If the operator aborts the copy: The disk will be given a "T3AB" tag, the disk cannot be enabled, the flag cannot be turned off, the disk family must be reinitialized (initialize family directory in a type 3 load) or run the disk copy to completion. If the operator skips sectors until the copy is complete: The disk will be given a "T3ER" tag, the flag will have to be turned off before the disk can be used. To reset the error flag: 1. Perform a type 3 load 2. Select initialization options 3. Select check file system tag 4. Select the disk 5. The flag will then be set to "INIT" and may then be enabled As can be seen from the above, never abort a disk copy if you can unless there is no other option! ORIGINATOR: Pete Dobrow & Ed Schmedes DISK I/O-CALCOMP-T-303------------------------------FIB041 Pg001 FIB 00042 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-303------------------------------FIB042 Pg001