MAI COMPANY CONFIDENTIAL FIELD INFORMATION BULLETIN SERVICE GROUP(S): MICRO,MINI MFG: RODIME NACS TYPE(S): N045 MFG. MODEL(S): 10MB,22MB,33MB,43MB CATEGORY: DISK I/O DESC: 5.25" FIXED MEDIA *** TABLE OF CONTENTS AS OF 12/03/91 *** FIB 00001.General Information.........................................08/22/91 FIB 00002.Ready light flashes - Error Codes...........................07/20/84 FIB 00003.Handling caution when drive is out of the system............01/21/85 FIB 00004.Disk Formatter Program For S/10.............................08/08/85 FIB 00005.Intermittent failures of 53 MB and 20 MB....................02/26/86 FIB 00006.System 2000 flaw maps, DUTIL-drive formatting...............08/07/86 FIB 00007.Don't format 1600 5-1/4" disk drives under BOSS Release 4.5S08/22/86 FIB 00008.Field upgrades of Rodime 10/22MB disk drive microprocessor..08/26/86 FIB 00009.Allow thermal equalization before formatting................04/27/87 DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------Table Of Contents Pg01 of 01 FIB 00001 08/22/91 *** General Information *** Rodime 5-1/4" disk drives are not true Winchester drives, in that the access mechanism is a stepper device as opposed to the voice coil/servoe head arrangement associated with the Winchester type. Drives currently serviced by MAI may have a capacity of: 10MB 22MB 33MB 43MB *** NACS MACHINE TYPES AND FEATURE NUMBERS *** 4122,4133,4292,4317,9292 *** AVAILABLE DOCUMENTATION *** DRIVE SPECIFICATIONS: FORMAT SIZE P/N HEADS SEC/TRA CYL BLOCKS 22MB TT524100 8 17 320 43248 33MB MM534055 6 17 640 65076 44MB MM534060 8 17 640 86768 MBF manual M8096 - 5-1/4" Winchester Disk Drive (RO Family) *** AVAILABLE TRAINING *** No formal training is available, as such. The service philosophy for the Rodime drives is replacement upon failure if reformatting does not resolve the problem ORIGINATOR: J. WHALEN DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB001 Pg001 FIB 00002 07/20/84 *** Ready light flashes - Error Codes *** The hard disk uses the ready light to flash error messages when certain fault conditions occur. During power up, the LED flashes at 0.5 second intervals. After 25 seconds maximum, the LED will stop flashing and remain on. This is the normal indication given if the drive has no failure coming ready. Model Time To Ready 10 meg 10 seconds 20 meg 18 seconds For the fault codes, a four-bit binary code is used. Long flash=logic 1 and a short flash=logic 0. The MSB (most significant bit) occurrs first. Led Flashes Code Cause S S S L 01 No index track data burst at track 2 or 3. S S L S 02 No flag 0 from track 0 detector. S S L L 03 Motor speed exceeds plus or minus 1% tolerance. S L S S 04 Motor speed exceeds plus 10% or minus 5% tolerance. S L S L 05 Flag 0 always true. S L L S 06 Step pulse while write gate true. S L L L 07 Static write fault condition. ** L S S S 08 N/A. L S S L 09 Microprocessor self-test failed. L S L S 10 No index. L S L L 11 Motor not up to speed. L L S S 12 Found index track burst but cannot set index. LED REMAINS OFF Firmware/microprocessor fault. LED REMAINS ON Firmware/microprocessor fault. LED FLASHES (erratic) Firmware/microprocessor fault. Note: **=Write fault conditions 1. Write current and no write gate. 2. No write current and write gate. 3. More than one read/write head selected. 4. 12V supply drops below 10.3V. 5. 5.5V supply drops below 4.5V. ORIGINATOR: R. Hofslund DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB002 Pg001 FIB 00003 01/21/85 *** Handling caution when drive is out of the system *** The mounting plate studs protrude thruough the shock mounts so that when the drive is placed on a flat surface the studs contact the flat surface and defeat the shock mounting. Under these circumstances it is imperative that all the Winchester Disk Drives be handled with extreme caution, Otherwise either the surface(s) or head(s) may be damaged. ORIGINATOR: J. Sanka DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB003 Pg001 FIB 00004 08/08/85 *** Disk Formatter Program For S/10 *** Original Document Name - Mini Alert 401 A new formatter program contained in Diagnostic Diskette No. 3 (P/N TT529080) is available. The new formatter is self loading so cpm is no longer needed. The new formatter requires the user to enter the disk capacity of the drive to be formatted. The old formatter determines the capacity by itself, sometimes erroneously. To use the new formatter, just insert the diskette in the floppy drive and boot from it, the program will load and print the monitor menu as follows: 4005 HARD DISK DIAGNOSTIC PROGRAM - REVISION B01*04.08 1. DISK DIAGNOSTIC PROGRAM 2. FORMAT UTILITY PROGRAM 3. TOGGLE PRINTER--CURRENTLY (OFF) The heading in the menu identifies the new revision level B01*04.08. The old formatter was revision level 1.1*12. All new orders will be filled with the new version. ORIGINATOR: J. VAN OORDT DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB004 Pg001 FIB 00005 02/26/86 *** Intermittent failures of 53 MB and 20 MB *** PROBLEM: Intermittent read failures Usually fails when the drive is cold in either of the following manners: 1. When booting the operating system from hard disk it fails to read the loader and the system jumps to DEBUG. 2. After reading the loader the system partially loads the operating system and then hangs. SOLUTION: The RODIME drives should be formatted during initial system installation and when a drive is installed as an add on or replacement. The RODIME drives ,due to the absence of a servo track are more susceptable to changes on head positioning may be affected by temperature variations and jarring during transportation. ORIGINATOR: J VAN OORDT DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB005 Pg001 FIB 00006 08/07/86 *** System 2000 flaw maps, DUTIL-drive formatting *** The necessity for keeping and maintaining an up-to-date flaw map for the WDD can not be overemphasized. This holds especially true with possible adaptec firmware problems, where blown formats may necessitate reformatting of the disk unit(s). Some systems may have been shipped without accompanying flaw maps for the disk drives (prior to 3/86). If you have such a system and your unit does not now have a current flaw map, make one at your earliest convience. It is up to you to make sure it can be used as a viable tool. A good format and surface analysis is absolutely essential for reliable operation of the disk unit. The following is suggested - - every disk should have a flaw map. It should include the MFG. list as well as the flaw map printed by the dutil program. - never format a drive unless necessary. You can determine this by running the disk diagnostics, concentrating on the seek tests and using the read- only option. Run the read-only verify option with ecc off to detect possible soft errors. (The error log should also be looked at to determine weak areas of the disk). - If the disk's flaw map is inadvertantly lost, a printout of the defect list can still be obtained by selecting printer command option sp or option lp while running under dutil, and then displaying the defect list. - If the drive has been formatted before and the service rep wishes to format, always use option #5 (update defect map). use option #$4 (format, no surface analysis, defect mapping) only if update defect map fails. Below are listed the various dutil options available; recommended procedures for using them and a concise explanation of what they do. OPTION: 1. Format, surface analysis, defect mapping - use this option to first format a disk unit as if there were no defects, then perform a surface analysis with hardware ecc and retries disabled. After surface analysis, the MFG defects are entered by the user. The surface analysis results are merged with the MFG defects to form a more complete list. (Use this option when no defects are known to exist, or when the defect list is lost). NOTE: Option 1 is the only formatting option which will do 2 formats on the disk; the first without defects, the second with the defect list just created. 2. Format only, no defect mapping - this is the quick format. use this option when no defects are desired, or none are to be mapped out. 3. Surface analysis, report results - surface analysis specifically for use after formatting. This analysis will destroy data on the disk. Use this option after the last formatting option is complete to ensure no further soft errors exist. If defects are found by this option, rerun option #5 to add new defects to flaw map. 4. Format, no surface analysis, defect mapping - this format option is intended to permit the user to enter known defects. This option does not DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB006 Pg001 use a previously saved defect list, it is intended primarily to manually enter defects. Option #3 should normally be run after this to ensure that no additional defects exist. 5. Updating defect map - this option is used to add a new defect to the existing defect list created by a previous format. Option #3 should have been run prior to this option. Error log information saved by the o/s is also an excellent source of intermittant bad spots. This option is the only one that uses the saved defect list. Use this option to reformat the disk unit with the old (original) defect list. To do this, simply carriage return when prompted for defects. If no saved defect list exists and no defects are entered, this option informs the user and no formatting will take place. 6. Change disk label - this option only changes the disk label in the superblock. The re-write operation will either take place immediately or during the next formatting process, at the user's option. If the choice is immediate, dutil will create a default label; if the choice is during formatting, the label can be user-defined. 7. Read maxtor defects from disk - only for maxtor disk units which have never been formatted under dutil. Defect list written on the drive by the mfg may be optionally re-written for later dutil use by the user. This eliminates the necessity to manually enter all defects. Do not select this option if the drive has been previously formatted by dutil. To check, use the read-only utilities menu and read defect list. To determine what to do and when, use the following parameters - CONDITION ACTION Maxtor drive never before formatted. option 7 Non-maxtor drive never before formatted and option 4, then option 3 defects are known. Non-maxtor drive never before formatted and option 1 no defects are expected or list is lost. Drive has been formatted before. option 5, then option 3 When defect list on the disk is corrupted. option 4 (enter all defects), then option 3, then option 5 if new defects are found Add a new defect list to an existing list. option 5 Reformat using existing list as a normal option 5 (enter C/R to maintenance procedure. "defect entry" prompt in order to use old list), then option 3, then option 5 if new defects are located To test format and data reliability option 1, read-only utilities The suggested number of surface analysis patterns for use is - as many as time will allow... the more patterns selected, the more thorough the analysis, and the more reliably the unit will operate. ORIGINATOR: P. Koehler DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB006 Pg002 DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB006 Pg003 FIB 00007 08/22/86 *** Don't format 1600 5-1/4" disk drives under BOSS Release 4.5S *** Under NO circumstances should Winchester disk units be formatted using the formatter utility supplied with the 4.5 "S" Operating System. If format is performed under this Operating System the procedure will most likely not complete properly or possibly ignore bad spots, resulting in a missing or incomplete bad spot list. Should you then try to use this disk after such a format, in the "as is" condition, you will see various operational errors relating to the fact that now the bad spots are not mapped out. The minimum Operating System level under which format should be performed is 4.5 "B". ORIGINATOR: Pete Koehler DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB007 Pg001 FIB 00008 08/26/86 *** Field upgrades of Rodime 10/22MB disk drive microprocessor *** OVER VIEW OF MICROPROCESSOR CHANGES 1. Modified motor speed check to eliminate spurious ERROR 4's 2. Delay in moving stepper motor at power up. 3. Delay in starting spindle motor to ensure brake solenoid is fully energized.. SYMPTOMS 1. Drive may report ERROR 4, because of noise induced occurences. 2. Drive may not come ready at power up. IDENTIFICATION OF STEPPER MOTOR AND MICROPROCESSOR PROGRAM 1. Pgm 6052-11 is designed to operate with stepper motor MOT0006. this motor has a wide black band around the stepper motor body. Any revision below -11 is not acceptable.(see FIGURE 1). 2. PGM 6097-6 is designed to operate with stepper motor MOT0050.this motor has a narrow black band around the stepper motor body. Any revision below -6 is not acceptable.(see FIGURE 1). RODIME PART NUMBER NACS PART NUMBER ----------------------------------------------------- PGM 6052-11 HD036052 PGM 6097-6 HD036097 NOTE: It is estimated that 90% of the field will use the PGM 6052 configuration. PROCEDURE 1. Identify the stepper motor type and select the appropriate version of microprocessor firmware. 2. Remove the four counter sunk screws retaining the facia. 3. Using a 6/32" hex allen key ,remove the six dome headed screws retaining the Master Electronics PCB. 4. Lift the Master Electronics PCB clear of the Preamplifier PCB and rotate through 180 degrees. 5. Disconnect the Master Electronics board from the Motor Speed Control PCB by removing the ribbon cable (J5) from connector (P5). 6. Locate the microprocessor (IC 22) on the Master Electronics PCB noting the orientation of the IC. 7. Observing proper anti static precautions carefully remove the microprocessor from its socket. 8. Insert the replacement ensuring correct orientation. 9. Replace Master Electronics PCB, ensuring correct pin alignment of the Master Electronics/Motor Speed Controll PCBs (J5/P5) and Master Electronics /Pre-amplifier PCBs (J4/P4). 10. Retest the drive. DRAWING INFORMATION: See Mini Alert 494 hardcopy for FIGURE 1. ORIGINATOR: JOHN OBRIEN DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB008 Pg001 FIB 00009 04/27/87 *** Allow thermal equalization before formatting *** When formatting or reformatting any Winchester Disk it is essential for temperature equalization to have been reached before the format is begun. Temperature equalization is the term used to describe the point in time when the disk platter, the read/write heads, and the air temperature within the disk drive housing reach their optimum operating temperature. Should a format procedure be performed on a "cold disk, one or more of the following symptoms may be seen: o hangs of the system causing a warm or cold boot to be performed. o Possible corrupted files o Failure to boot the system at random intervals. In the case of Winchester style disk drives, the following parameters should be met before any attempt to format the disk is begun: o If the drive has been turned off for periods in excess of one hour: Let drive run for a minimum of thirty minutes before attempting to format. o If the drive has been turned off for less than one hour: Let drive run for twenty minutes before formatting. o If drive has been turned off for less than one hour and room temperature is subject to a fluctuation of ten degrees centigrade or more per hour: Let drive run for thirty minutes before formatting. Following the conditions above will assure that the format will have been performed under the same ambient conditions found during normal operation of the system. ORIGINATOR: P. KOEHLER DISK I/O-RODIME-10MB,22MB,33MB,43MB-----------------FIB009 Pg001