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AC Repair and Adjustment Procedures

FRP 3: Power Supply Replacement

HMM-168-A

Cray Research/Silicon Graphics Proprietary

23

8.

Set the old power supply and the replacement power supply on an
ESD-safe work area.

WARNING

The power supply weighs
approximately 30 lbs (15 kg). Remove
the power supply carefully. It is heavy
and may cause back injury, or it may
cause injury if it falls on someone.

Summary of Contents for T3E

Page 1: ...xiliary Clock Power Supply Replacement 29 FRP 5 Module Replacement 32 FRP 6 Daughter Card Replacement 42 FRP 7 Power Supply Rail Replacement 49 FRP 8 Top Module Rail Replacement 52 FRP 9 Bottom Module Rail Replacement 59 Cables FRP 10 Logic Cable Replacement 65 FRP 11 GigaRing Cable Replacement 71 FRP 12 Clock Wire Replacement 76 FRP 13 Boundary Scan Cable Wire Replacement 87 FRP 14 Module to WACS...

Page 2: ...lacement 152 FRP 30 WACS Panel Circuit Breaker CB8 CB9 or CB10 Replacement 156 FRP 31 Power Supply Circuit Breaker CB2 through CB7 Replacement 160 Power Box Components FRP 32 Voltage Selector Switch SW1 Replacement 164 FRP 33 Time delay Relay Replacement 168 FRP 34 Line Filter FL1 Replacement 170 FRP 35 Contactor CT1 Replacement 173 FRP 36 Resistor R1 Replacement 176 Cooling Components FRP 37 Air ...

Page 3: ...ng January 1998 Revision A Added information on module pin protectors Added steps for packing a module in a shipping container to the module replacement procedure Made minor technical corrections elsewhere March 1998 Revision A 1 Updated the power supply removal procedure with information about the appropriate tools to use in order to avoid stripping hex bolts ...

Page 4: ...ing general instructions apply to all procedures in this document Review the entire procedure before you perform any steps Remember that the tools list for a given procedure does not include the hex wrench required to open cabinet doors or the tools required to complete additional tasks that are documented under a different procedure Label or otherwise record the locations of every wire or cable t...

Page 5: ...ter Board Assy 1 2 pop 16Meg 70 NS 32MB Variable Yes 15158500 Daughter Board Assy 1 2 pop 16Meg 60 NS 32MB Variable Yes 15104601 Daughter Board Assy Single Hi 16Meg 70 NS 64MB Variable Yes 15158100 Daughter Board Assy Single Hi 16Meg 60 NS 64MB Variable Yes 15104001 Daughter Board Assy 2Hi Stack 16Meg 70 NS 128MB Variable Yes 15158300 Daughter Board Assy 2Hi Stack 16Meg 60 NS 128MB Variable Yes 15...

Page 6: ...No 57251100 Couple In line 8 wire RJ45 5 No 57263800 Cable Assy clock to WACS T3E AC 1 No WACS Components 15135901 IC Micro T3E Air WACS 1 Yes 15130000 Thermistor Assy Module Temperature 4 No 31445000 Module Assy Disk IOSF Display 1 Yes 31504104 Module Assy IOSF T3E Air WACS scanner 2 Yes 57199600 Thermistor Assy Air Flow 4 No 57199700 Thermostat 65 Degree C 2 No Switches 57185700 Switch 600V 40A ...

Page 7: ...s 55091902 Relay Time Delay 1 No 57168800 Filter Power 45 Amp 1 No 57186100 Contactor 4 Pole 65 Amp 600V 1 No 57185400 Resistor 50W 330 Ohm 1 No 57185700 Switch 600V 40A 5 Stage Voltage Selector 1 No 57186100 Contactor 4 Pole 65 Amp 600V 1 No 57170001 Cordset IEC320 20A 480V 1 No Blower Blower Speed Control Components and Air Filter 57067701 Controller Power SCR 20A W XFMER transformer 1 No 570819...

Page 8: ...PHH M3 8MM 13159002 Screw Mach PNH PHH M4 6MM 13159003 Screw Mach PNH PHH M4 8MM 13159004 Screw Mach PNH PHH M4 10MM 13160602 Washer Plain M3 13160603 Washer Plain M4 13161502 Washer Lock M3 13161503 Washer Lock M4 13249901 IC Micro PWR Subrack 13264101 Power Supply T3E FRU 15130000 Thermistor Assembly Module Temperature 15135901 IC Micro T3E Air WACS 15215600 Spring Rail 15223701 Wire Assy Clock ...

Page 9: ...4900 Screwdriver Set Phillips 01524901 Screwdriver Set Flat Blade 01525001 Wrench Set 1 4 Drive 01525400 Screwdriver Set Torque 01529400 Holder Hemostat Curved 01529401 Holder Hemostat Straight 01529903 Battery D Cell 01531200 Mirror Inspection TLSCP 01531700 Tweezers Micro 01532400 Magnet Parts Pick up 01563600 Screwdriver PH Hard Tip 01596700 Probe Kit 12277700 Cable Assy Test Lead Ohming 128047...

Page 10: ...modify CRAY Y MP carts for use with both CRAY Y MP and CRAY T3E modules by installing two rails P N 13267700 15255800 Flashlight 15256900 Flashlight NightHawk Microlight 35717400 Wrench Set Balldriver Hex 050 5 32 51908400 Pliers Needle Nose 90334800 Tape Cleaner HD 4MM ME107389 Tool Assy Daughter Board Removal Table 3 Tool Kit 57247800 Part Number Description ...

Page 11: ... door The figure shows access panels wire ducts and various cabinet components Figure 1 Access Panels Ducts and Components Front Left View Upper Logic Panel Logic Wire Duct Logic Wire Duct with Frame Joiner Duct Attached Lower Logic Panel Restart Remote Enable and Margin Switches WACS Panel Power Supply Power Supply Breakers Power Box Main Disconnect CB1 Blower Fan Inlet Thermistors on wire duct c...

Page 12: ...that you must remove to replace modules or cables and it shows wire duct covers that you must remove in order to add cabinets or remove aesthetic panels The figure also shows the locations of the wrist strap plugs which are near the modules Figure 2 Access Panels Rear Left View Lower Logic Panel Blower Exhaust Shield Upper Plenum Panel Lower Plenum Panel Module Panel I O Panel Upper Rear Wire Duct...

Page 13: ... hex wrench into the latch and turn the latch counterclockwise 1 4 turn Refer to Figure 3 2 Grasp the door and swing the door open Each door contains a hole that aids in door opening You may insert a tool such as a 2 Phillips screwdriver in the hole to improve your grip and serve as a door handle On the front door the hole is on the top of a raised panel near the middle right side of the door as s...

Page 14: ... and Handle Front Door Door Removal Procedure 1 Open the door 2 Use a Phillips screwdriver to disconnect one end of the ground wire that connects to the top of the door 3 Disconnect the Cabinet Power switch connector front door only The connection is near the top left corner of the front door Door Latch 1 4 turn Door Latch 1 4 turn Insert Tool Here and Pull ...

Page 15: ...rtical studs of the chassis hinge assembly 2 Carefully position the door s hinge hardware directly above the frame hinge pins NOTE You may need to flex the door slightly to align the hardware 3 Carefully lower the door onto the frame hinge pins 4 Ensure that the door opens and closes properly 5 Connect the Cabinet Power switch connector front door only and the ground wire then close the door for n...

Page 16: ...anel Removal Procedure NOTE This procedure requires two people 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the rear cabinet door 4 Disconnect the cable from the clock switch board Two flathead screws sec...

Page 17: ...r the input power access plate However if you loosen the bottom center screw on the wire duct cover you may be able to rotate the wire duct cover out of the way 7 If you plan to remove the left panel disconnect the connector for the Cabinet Power switch SW2 The connection is located near the top stud retaining bolt on the power supply end of the left panel Figure 4 Side Panel Bolt and Wire Duct Lo...

Page 18: ... the top retaining studs Again be careful not to drop any nuts or washers 10 Remove the panel a With a partner carefully lift the panel slightly then pull it straight out from the side of the cabinet Keep the panel in a vertical position b Set the panel in a protected location WARNING Remove the panel carefully the side panel may start tipping The panel is heavy and will cause injury if it falls o...

Page 19: ...AC Repair and Adjustment Procedures FRP 2 Removing the Cabinet Side Panel HMM 168 A Cray Research Silicon Graphics Proprietary 19 Figure 5 Removing Side Panels Spacer Stand off Spacer Stand off Stud ...

Page 20: ...h the holes until the panel contacts the frame 2 While your partner holds the panel in position replace the washers and nuts on the retaining studs Secure the nuts 3 Reconnect the Cabinet Power switch SW2 if necessary 4 Replace the wire duct panels 5 Replace the blower exhaust shield and connect the clock switches 6 Return the cabinet to operation and close the front and rear cabinet doors WARNING...

Page 21: ...ly s output connector NOTE Refer to FN 2440 for information on isolating and tracking Phase 4 and Phase 5 power supply problems Part Number 13264100 power supply 3 3 Vac with thermal pad Tools Required Small flatblade screwdriver 2 0 mm 2 5 mm and 3 0 mm hex sockets with torque driver The sockets are included in Socket set Hex Bit 1 4 Drive Metric P N 53267200 which is part of the T3E Tool Kit P N...

Page 22: ...to restrict air flow through the power supply b Remove the upper power cord connection and set the cord aside 5 Use a small flatblade screwdriver to disconnect the control connector from the defective power supply 6 Use a 2 mm hex wrench to loosen the retaining screw setscrew at the bottom of the power supply handle It is not necessary to remove it from the power supply handle 7 Remove the power s...

Page 23: ...Silicon Graphics Proprietary 23 8 Set the old power supply and the replacement power supply on an ESD safe work area WARNING The power supply weighs approximately 30 lbs 15 kg Remove the power supply carefully It is heavy and may cause back injury or it may cause injury if it falls on someone ...

Page 24: ...pair and Adjustment Procedures 24 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 6 Power Supplies and Interlocks End View Retaining Screw Control Connection Step 7 Step 6 Power Supply In Place Power Supply Removed Power Cord ...

Page 25: ...riginal positions b Loosen the four 3 mm hex bolts and washers that hold the heat sink to the power supply refer again to Figure 7 Leave the bolts in the heat sink after you loosen them The bolts are different lengths and must remain in their original positions c Pull the heat sink off of the power supply with firm upward pressure It may be necessary for you to gently pry the heat sink loose at a ...

Page 26: ... with a small flatblade screwdriver or with needle nose pliers Figure 7 Heat Sink Replacement 3 Put the heat sink on the replacement power supply a Position the replacement thermal pad on the power supply NOTE It is not necessary to apply thermal compound b Position the heat sink on the power supply align the bolts or bolt holes in the heat sink with the bolt holes on the power supply c Install th...

Page 27: ...er supply assembly with the slots in the power supply rails then insert the supply partially into the rails with even pressure c When the power supply handle is near the upper mechanical interlock rotate the interlock until its slot aligns with the power supply handle d Ensure that the slot in the lower interlock aligns with the power supply handle If not rotate the lower interlock e Fully insert ...

Page 28: ...ly 5 Close the power supply circuit breaker 6 When you are ready to apply power to this module slot take all necessary steps to restore the associated module to a functional state For example reconfigure the torus configuration and press the Restart button switch on the WACS panel When you press the Restart button the WACS sends enable signals to all power supplies with functional modules This doe...

Page 29: ...modify the procedure as needed Part Number 15258000 power supply assembly dual output clock Tools Required Short handled 2 Phillips screwdriver Small flatblade screwdriver Power Supply Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet You may also open lock and tag the customer s wall breaker s 3 Open the secondary circuit breaker...

Page 30: ...k Power Supply Replacement AC Repair and Adjustment Procedures 30 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 8 Clock s Auxiliary Power Supply Location Main Disconnect CB1 Circuit Breaker CB10 Power Supply ...

Page 31: ...ips screwdriver Four M4 screws with washers secure the power supply to the top of the WACS box Power Supply Installation 1 Position the replacement power supply in the cabinet 2 Secure the power supply to the top of the WACS box with the 4 Phillips screws and washers 3 Connect the control cable to the power supply 4 Connect the power cord to the power supply 5 Return the system to operation and cl...

Page 32: ...o determine the part number that you should order Never install daughter cards of different memory size on the same PEM Never place a PEM with an EV5 6 processor in a machine that has been running only EV5 processors unless the module slots have been checked for proper wiring and auxiliary voltage per FCO 3198 If you are not sure whether the slots were checked contact Technical Support When orderi...

Page 33: ...ircuit breaker The green AC power LED on the power supply should no longer be illuminated and the DC power LED on the module should no longer be illuminated 4 Remove the module panel from the rear of the chassis Eight 1 4 turn captive screws secure the module panel 5 Uncam the module a Remove the plastic shuttle locks if present from the camming guides b Insert the metal camming tool in the innerm...

Page 34: ...AC Repair and Adjustment Procedures 34 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 10 Module Camming 6 Use a 3 mm hex wrench to remove the retaining screw setscrew from the module handle Uncams Cams Cams Uncams ...

Page 35: ... If the interlocks did not rotate and close the rail dampers rotate the interlocks by hand c When the module is halfway out of the cabinet place one hand on the underside of the module heat sink assembly for support For example place your right hand flat with palm up beneath the module NOTE Ensure that you do not touch the logic components with your skin or clothing d With one hand on the module h...

Page 36: ...odule that you removed carefully install pin protectors P N 15145700 on any exposed daughter card pin connectors on the module Figure 12 shows a pin protector 11 Pack the module in an approved shipping container for return to Chippewa Falls Refer to Packing a Module in a Shipping Container on page 38 Figure 12 Pin Protector WARNING The module weighs approximately 40 lbs 18 kg Remove the module car...

Page 37: ...nical interlock rotate the interlock until the slot aligns with the module handle d Partially insert the handle into the lower mechanical interlock then release the lower interlock Now rotate the upper interlock until the slot aligns with the module handle e Fully insert the module then release the upper interlock Press firmly to ensure a good connection of module and power supply 3 Install the re...

Page 38: ...ice run bscan then run scan clear 8 Check the WACS display and the power supply and module power indicator LEDs 9 Close the front and rear cabinet doors Packing a Module in a Shipping Container 1 Ensure that the defective module contains plastic cams shuttle connector locks P N 12919100 and that all exposed daughter card pin connectors are covered by pin protectors P N 15145700 Figure 13 shows a p...

Page 39: ...and the handle facing the right 6 Place the top die cut foam over the module 7 If the module contains daughter cards roll up the sheet of filler foam and place it over the module handle If the module does not contain daughter cards place the unrolled sheet of filler foam over the top die cut foam 8 Close the inner box then pass the retaining strap beneath the box handle and snap the two ends of th...

Page 40: ... Repair and Adjustment Procedures 40 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 14 Module Shipping Container Inner Box Filler Foam Top Die cut Foam Module in Protective Bag handle on the right Bottom Die cut Foam ...

Page 41: ...AC Repair and Adjustment Procedures FRP 5 Module Replacement HMM 168 A Cray Research Silicon Graphics Proprietary 41 Figure 15 Module Shipping Container Outer Box ...

Page 42: ...ules and for current PEM clock and daughter card part numbers Part Number One of the following replacement daughter cards 15104001 daughter board assy 128MB 15104601 daughter board assy 64MB 15107601 daughter board assy 256MB 15108200 daughter board assy 512MB 15108400 daughter board assy 1024MB 15148500 daughter board assy 128MB 15148700 daughter board assy 256MB 15158100 daughter board assy 64MB...

Page 43: ...use ESD mat 01613600 and static monitor 01713901 you must connect ground straps as noted in the following list refer to Figure 16 One strap between the static monitor and the ESD mat One strap between the static monitor and the module One strap between the static monitor and your wrist strap Figure 16 Static Monitor and ESD Mat CAUTION Observe all ESD precautions Failure to do so could result in d...

Page 44: ... to Figure 17 Figure 17 Retaining Screw Locations 5 Position one leg of the daughter card removal tool in each of the 4 daughter card notches then engage the leg hooks with the daughter card cold plate Refer to Figure 18 NOTE You may need to squeeze the top sides of the tool to ensure that the legs pass through the notches 6 Lift the daughter card removal tool and daughter card directly away from ...

Page 45: ...ilicon Graphics Proprietary 45 Figure 18 Daughter card Removal Tool Placement 8 If you plan to store or ship a PEM install pin protectors P N 15145700 on all exposed daughter card pin connectors on the PEM Refer to Figure 19 Figure 19 Pin Protector Step 5 Guide Pin Pin Protector Retaining Screw ...

Page 46: ...re that no pins are bent or crushed 3 Carefully place the replacement daughter card in position on the motherboard The daughter card is keyed to install in one position only Align the holes on the daughter card with the guide posts and screw posts on the motherboard 4 When the daughter card is in position use your fingers to gently seat the daughter card The pins should slide gently into place as ...

Page 47: ...EM s input power bus and ground to ensure that no voltage to ground short exists Refer to Figure 21 NOTE In most cases EV5 PEMs indicate less resistance than EV5 6 PEMs b If the resistance on any PEM is 10 ohms or less remove the daughter cards one at a time and check for bent pins Retest after you remove each daughter card Repair any bent pins if possible If either the daughter card or motherboar...

Page 48: ...FRP 6 Daughter Card Replacement AC Repair and Adjustment Procedures 48 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 21 Ohming the PEM 3 4 Vdc Input Power Bus Ground Bus ...

Page 49: ...the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the power supply from the defective rail and remove the adjacent power supplies to provide access Refer to FRP 3 4 Use the hex wrench to remove the 4 shoulder screw...

Page 50: ...gure 22 Power Supply Rails 5 If necessary cover the air slot with a slot cover Two 3 Phillips screws hold the slot cover in place CAUTION To prevent a top rail from falling when youremovetheshoulderscrews ensure that you or a partner hold the rail in place while you remove the screws Upper Rail Lower Rail Shoulder Screw Locations ...

Page 51: ...sition the new rail in the module box card cage Place the module end of the rail against the brace crossbar in the module box 4 Secure the rail with the shoulder screws a Insert the screws that you removed Tighten all screws finger tight b Ensure that the rail is aligned with the module You may want to insert the power supply to ensure alignment c Tighten the screws securely 5 Carefully replace th...

Page 52: ...emat and double check your work especially the intricate wiring and connections Part Number One of the following parts 57251800 rail assembly clock module top 57255300 rail assembly PEM top 01775900 pin connector locks Tools Required 4 mm hex allen wrench with hex driver Small flatblade screwdriver 5 mm socket wrench 1 2 and 3 Phillips screwdrivers 0 3 mm mechanical pencil with no lead or a wire r...

Page 53: ...to the wires and cables Six 1 Phillips screws hold the panel in place NOTE If the torus interconnections clock connections and boundary scan connections of the rail that you are removing are in a different cabinet than the rail you must access the wiremats in all appropriate cabinets In addition you must open the intercabinet cable ducts as described in the following step 8 If the rail s wires and...

Page 54: ...ng the Phillips screws on the assemblies Figure 23 Intercabinet Cable Ducts as viewed from inside cabinet 9 Remove the module where you will replace the rail and remove one or more adjacent modules to provide access to the rail Refer to FRP 5 Put the modules in a protected location that is ESD safe Closed Cable Duct Open Duct Foam Strips Duct Seal Duct Seal Retaining Screws Open Cable Duct ...

Page 55: ...e associated logic torus wiremat connections that you must remove along with the rail Refer to FRP 10 13 Disconnect the associated boundary scan connections in the wiremat In most cases the only boundary scan connections to the rail take place via the PEM to scan pigtail P N 15214300 which contains 5 pluggable connections in the wiremat NOTE The scan master PEM in slot 1 of cabinet 0 also contains...

Page 56: ...lder screw from the other end of the rail 19 Carefully remove the defective rail a Check again to ensure that the wires and cables that connect to the rail are ready for removal with the rail b Angle the rail toward the floor and slowly slide it down and out of the cabinet Be careful not to damage any wires as you remove the rail and attached cables 20 If necessary cover the air slot with a slot c...

Page 57: ... it until fully inserted then unscrew it 1 revolution This screw will help hold the rail in place during the installation 4 Ensure that the wires and cables on the new rail are not in positions that will interfere with rail installation or cause wire damage during the installation If another person is available have that person guide the wires through the slot in the following step If another pers...

Page 58: ... or give It should move slightly toward the power supply when pushed k Insert a module refer to FRP 5 to ensure that the rail aligns with the power supply l Carefully remove the module Try not to move the rails when you remove the module m Tighten the two shoulder screws 6 Connect the associated wires and cables refer to the notes you took earlier and to the applicable wiring procedures in this do...

Page 59: ...onnector locks Tools Required 4 mm hex allen wrench with hex driver 1 2 and 3 Phillips screwdrivers Small flatblade screwdriver 1 4 in socket wrench 0 3 mm mechanical pencil with no lead or a wire removal tool for PEM 0 and clock modules Flashlight Tweezers Rail Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout dev...

Page 60: ...inets In addition you must open the intercabinet cable ducts as described in the following step 6 If the rail s wires and cables pass from one cabinet to another open the cable ducts where the cable passes between cabinets a Use a 1 Phillips screwdriver to loosen the five Phillips screws that secure each air seal assembly on the cable ducts b Lower the air seal assemblies to provide room for the c...

Page 61: ...e I O bulkhead PEM rails only Use a 1 4 in socket wrench to remove the two jackpost screws that secure the GigaRing connector to the I O bulkhead c If you are removing the bottom clock rail disconnect the clock WACS connection at the I O bulkhead Two small flathead screws secure the WACS cable to the bulkhead d If you are removing the bottom clock rail record and disconnect the associated clock wi...

Page 62: ...y use a 3 Phillips screwdriver to remove the slot cover from the slot Necessary during an upgrade 3 Ensure that the shoulder screw near the power supplies is installed Tighten it until fully inserted then unscrew it 1 or 2 revolutions This screw will help hold the rail in place during the installation 4 Ensure that the wires and cables on the new rail are not in positions that will interfere with ...

Page 63: ...t should move slightly toward the power supply when pushed h Insert a module refer to FRP 5 to ensure that the rail aligns with the power supply i Carefully remove the module without moving the rails j Tighten the two shoulder screws 5 Connect the associated wires and cables refer to the notes you took earlier Secure the wires and cables as needed 6 If applicable close the air seals on the cable d...

Page 64: ...FRP 9 Bottom Module Rail Replacement AC Repair and Adjustment Procedures 64 Cray Research Silicon Graphics Proprietary HMM 168 A ...

Page 65: ...er 15112904 X dimension ribbon cable assembly 15112905 Y dimension ribbon cable assembly 15112906 Z dimension ribbon cable assembly Tools Required 2 mm 4 mm and 0 05 in hex allen wrenches with torque driver 1 and 2 Phillips screwdrivers Medium flatblade screwdriver Tweezers optional Cable Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the ...

Page 66: ...um in place four of the screws pass through the top of the I O bulkhead 7 To access a cable in the Z side top wiremat Use a small flatblade screwdriver to disconnect the clock cable from the clock switch board 8 To access a cable in the Z side top wiremat Use a 2 Phillips screwdriver to remove the blower exhaust shield NOTE If the torus interconnections of the cable that you are removing are in a ...

Page 67: ...wdriver that fits the screws snugly Be careful not to damage or lose any screws Set the screws in a secure location 13 Slide the slot guide out of the rail horizontally Figure 24 shows the slot guide 14 Remove the defective cable a Return to the wiremat area and carefully remove the foam from the connector slot where the defective cable enters the rail tweezers may be helpful Each connector slot c...

Page 68: ...le Replacement AC Repair and Adjustment Procedures 68 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 24 Slot Guide Screws Connector Screws and Slot Foam Foam Nylon Screws 7 Hex Screws 2 Plastic Slot Guide ...

Page 69: ... Research Silicon Graphics Proprietary 69 Figure 25 Torus Cable Connections Pin 20 Pin 21 Pin 1 Pin 40 Alignment Grooves P2 P2 P3 P3 Interconnects End View End View Socket 1 Socket 20 Socket 21 Socket 40 Alignment Guides Connecting P2 P3 Rail P1 Connector Rail P1 Connector P2 to P3 ...

Page 70: ...en the 7 nylon screws that secure the slot guide in the rail When you have installed all 7 screws tighten the screws until you feel resistance Do not overtighten the screws but ensure that the screwheads are recessed within the slot guide 4 For a torus cable connect the cable in the wiremat a Determine where the replacement cable connects and connect it b Coil the two cables that you just connecte...

Page 71: ...ins mounted in the chassis Part Number 15200500 cable assembly GigaRing to bulkhead Tools Required 2 mm 4 mm and 0 05 in hex allen wrenches with torque driver 1 and 2 Phillips screwdrivers Medium flatblade screwdriver 1 4 in socket wrench Tweezers optional Cable Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout dev...

Page 72: ...e modules in a protected location that is ESD safe 8 Remove the 7 nylon screws that hold the plastic slot guide to the rail Refer to Figure 27 Use a medium flatblade screwdriver that fits the screws snugly Be careful not to damage or lose any screws Set the screws in a secure location 9 Slide the slot guide out of the rail horizontally Figure 27 shows the slot guide 10 Disconnect the cable at the ...

Page 73: ...ecure the defective cable to the wire rack 14 Return to the module side of the rail and use the 0 05 in hex wrench to remove the 2 hex screws and brass spacer if applicable that secure the connector to the rail Refer to Figure 27 Be careful not to lose any screws set the screws in a secure location The screws are P N 13033501 The brass spacer is P N 12755600 15 Slide the connector toward the air d...

Page 74: ...placement cable in the wiremat Ensure the proper orientation of the connector on the module end of the cable then push the connector through the connector slot in the rail b Position the connector in the connector slot and insert the hex screws and brass spacer if applicable Tighten the screws to 15 in oz c Push the connector toward the spring to ensure that the connector moves laterally then spri...

Page 75: ...e I O bulkhead a Route the replacement cable to the I O bulkhead and position it in the appropriate connector slot b Use a 1 4 in socket wrench to install the two jackpost screws that secure the connector to the I O bulkhead Tighten the screws hand tight c Secure the cable to the wire rack with a tie strap 5 Swing the I O bulkhead into operating position and secure it with screws 6 Replace and cam...

Page 76: ...work Part Number One or more of the following clock wire assemblies 15223701 wire assembly system clock 15224008 wire assembly GigaRing clock 15244601 wire assembly master system clock 01775900 pin connector locks Tools Required 2 mm and 4 mm hex allen wrenches with hex driver 1 and 2 Phillips screwdrivers Camming tool Medium flatblade screwdriver 0 05 in hex allen wrench with torque driver 0 3 mm...

Page 77: ... you are replacing a clock wire in the Z side top wiremat disconnect the cable from the clock switch board remove the blower exhaust shield and remove the upper plenum panel Six 2 Phillips screws hold the blower exhaust shield in place Six 1 Phillips screws hold the upper plenum in place If you are replacing a clock wire in the Y side bottom wiremat remove the I O panel and the lower plenum panel ...

Page 78: ...llips screws that secure each air seal assembly on the cable ducts b Lift or lower in the case of the Y side wiremat the air seal assemblies to provide room for the wire The air seal assemblies contain slots that move up and down on the Phillips screws c Secure the air seal assemblies in the open position by tightening the Phillips screws on the assemblies Figure 28 Intercabinet Cable Ducts as vie...

Page 79: ...t where the clock wire enters the rail Each connector slot contains an oval piece of foam which tears easily Figure 29 Connector Foam Plug 11 To aid you in dropping the connector into the card cage loosen the wires that plug into the connector where the defective wire is located In other words remove tie straps that secure the wires to the wire rack in that cabinet Do not unbundle the wires 12 Pla...

Page 80: ...ng Remove it only if it comes off easily You may insert one end of a tweezer tip between the spring and the rail and pry the connector loose as shown in Figure 31 Place the spring in a secure location NOTE Removing the spring ensures that you do not accidently wrap a wire around the spring when you reinsert the connector If you guard against this you may leave the spring on the rail NOTE This figu...

Page 81: ...tic connector pin lock P N 01775900 from the module side of the connector Refer to Figure 32 You will replace the pin lock with a new one Figure 32 Removing a Connector Pin Lock 17 Use a 0 3 mm mechanical pencil or a wire removal tool to release the clock wire from each rail connector a Position yourself so that you can see the clock wire pins b Identify the pin location of the defective wire Spri...

Page 82: ...3 Connector Removal with Mechanical Pencil 18 Repeat Step 9 through Step 17 for the other end of the clock wire 19 Use snips to cut off one end of the defective wire Then gently pull the other end of the defective wire to determine if you can remove it from the wiremat If you cannot remove the defective clock wire cut off the other end of the defective wire as well to avoid potential confusion at ...

Page 83: ...ment clock wire above or below in the case of the GigaRing synchronization wire the appropriate pin slot in the rail connector Pin slot 1 is marked with red in most cases Pin slot 2 is directly across from pin slot 1 Ensure that the 2 pin connector is oriented with the pin lock wavy side toward the outside of the connector as shown in Figure 34 Figure 36 on Page 86 shows the process using a wire i...

Page 84: ...Use a dental pick to insert the pin lock as shown in Figure 35 6 From the wiremat side gently pull the connector block up toward the other rail connectors Figure 35 Inserting and Seating a Plastic Connector Pin Lock 7 Ensure the proper orientation of the connector then position the connector in the connector slot and insert the hex screws and brass spacer if applicable Tighten the screws to 15 in ...

Page 85: ...rings back into position 10 Insert the foam plug in each connector slot 11 Use tie wraps to secure the clock wire in the wiremat 12 If applicable close the air seals on the cable ducts where wires pass between cabinets 13 Replace and cam the modules that you removed Refer to FRP 5 14 Reinstall any panels that you removed earlier 15 Return the system to operation ensure proper function and close th...

Page 86: ... Ensure that theplastictiponthewirerodisatthewire insertion end of the connector block and ensure that the slanted portion of the cavity in the plastic tip faces the outside of the connector block Then insert the 2 pin connector into the cavity as shown at left The cavity pinches the pins together as you insert the connector 2 3 4 Pull the rod through the connector block to insert the 2 pin connec...

Page 87: ... Part Number One or more of the following cable or wire assemblies 15214300 cable assembly PEM to scan pigtail 15223701 wire assembly clock internal 15223802 cable assembly scan jumper 15223900 wire assembly termination VDD SME 15224009 wire assembly edge to edge 15237601 cable assembly edge to pigtail 2 position socket 15237701 cable assembly edge to pigtail 4 position pin 15237801 cable assembly...

Page 88: ...nnect the cable from the clock switch board 5 Use a 2 Phillips screwdriver to remove the blower exhaust shield Six 2 Phillips screws hold the shield in place 6 Loosen the eight 1 4 turn captive screws that secure the module panel then pull the module panel out of the cabinet at an angle 7 Remove the upper plenum panel to provide access to the wire assembly Six 1 Phillips screws hold the panel in p...

Page 89: ...blies contain slots that move up and down on the Phillips screws c Secure the air seal assemblies in the open position by tightening the Phillips screws on the assemblies 9 Remove the clock module and or the PEM where the defective wire assembly connects Then remove additional modules to provide clear and safe access to these rails Refer to FRP 5 Put the modules in a protected location that is ESD...

Page 90: ... unbundle the wires 15 Place ESD safe foam or plastic in the bottom of the card cage to catch any screws etc that you might drop in subsequent steps 16 Use the 0 05 in hex wrench to remove the 2 hex screws and brass spacer if applicable that secure the connector to the rail Then loosen but do not remove the remaining hex screw in the adjacent connector that is closer to the power supply Refer to F...

Page 91: ...mes off easily You may insert one end of a tweezer tip between the spring and the rail and pry the connector loose as shown in Figure 39 Place the spring in a secure location NOTE Removing the spring ensures that you do not accidently wrap a wire around the spring when you reinsert the connector If you guard against this you may leave the spring on the rail NOTE This figure shows all screws and co...

Page 92: ...h Silicon Graphics Proprietary HMM 168 A Figure 39 Removing a Connector Spring 19 Use a dental pick or some other sharp tool to carefully remove the plastic pin lock P N 01775900 from the module side of the connector Refer to Figure 40 You will replace the pin lock with a new one Spring Tweezers ...

Page 93: ...tify the pin location of each wire in the wire assembly for example pin location zaf04 Record the locations c For each boundary scan pin connector that you must disconnect Carefully slide the hollow tip of the pencil over the outermost pin of the pin pair Then apply a gentle force both toward the other pin in the pin pair and toward the wire away from the module area and toward the base of the rai...

Page 94: ... Proprietary HMM 168 A Figure 41 Connector Removal with Mechanical Pencil Slip the hollow point of the pencil over the outer pin Gently angle the pencil so that the outer pin bends toward the inner pin This releases the pin lock Push the 2 pin connector out of the rail connector Latch Pencil Rail Connector Step 20 ...

Page 95: ... 2 pin connector above the appropriate pin slot in the rail connector Pin slot 1 is marked with red in most cases Pin slot 2 is directly across from pin slot 1 Ensure that the 2 pin connector is oriented with the pin lock wavy side toward the outside of the connector as shown in Figure 42 Figure 44 on Page 98 shows the process using a wire insertion rod b Use your fingers or an appropriate tool su...

Page 96: ...a plastic connector pin lock P N 01775900 in each rail connector and ensure that the pins are straight Use a dental pick to insert the pin lock as shown in Figure 43 If the wire assembly that you are replacing does not have a connection in the wiremat then you must perform the previous steps for both ends of the cable Figure 43 Inserting and Seating a Plastic Connector Pin Lock Place curve of dent...

Page 97: ...nector spring and center it in relation to the connector block 9 Push the connector toward the spring to ensure that the connector moves laterally then springs back into position 10 Insert the foam plug in each connector slot 11 If applicable connect the boundary scan wire s in the wiremat 12 Use tie wraps to secure the clock wire in the wiremat 13 If applicable close the air seals on the cable du...

Page 98: ...as shown Ensure that theplastictiponthewirerodisatthewire insertion end of the connector block and ensure that the slanted portion of the cavity in the plastic tip faces the outside of the connector block Then insert the 2 pin connector into the cavity as shown at left The cavity pinches the pins together as you insert the connector 2 3 4 Pull the rod through the connector block to insert the 2 pi...

Page 99: ...g procedures are more efficient when two people work together The individuals can share tasks and check one another s work Part Number One of the following cable assemblies 15214200 cable assembly PEM to WACS 57263800 cable assembly clock to WACS 01775900 pin connector lock Tools Required 2 mm 4 mm and 5 mm hex allen wrenches with hex driver 1 and 2 Phillips screwdrivers Camming tool Small and med...

Page 100: ...re If you are replacing a PEM to WACS cable Disconnect the cable from the clock switch board remove the blower exhaust shield and remove the upper plenum panel Six 2 Phillips screws hold the blower exhaust shield in place Six 1 Phillips screws hold the upper plenum panel in place If you are replacing a clock to WACS cable Remove the I O panel loosen the I O bulkhead and remove the lower plenum pan...

Page 101: ...r slot contains an oval piece of foam which tears easily Refer to Figure 45 Figure 45 Slot Foam Plug 9 Ensure that there is enough slack in the WACS cable and any other wires that connect to the same connector to enable you to pull the connector into the card cage In other words remove tie straps that secure the WACS cable and any other wires to the wire rack 10 If you are replacing a PEM to WACS ...

Page 102: ...y the connector loose as shown in Figure 47 Place the spring in a secure location NOTE Removing the spring ensures that you do not accidently wrap a wire around the spring when you reinsert the connector If you guard against this you may leave the spring on the rail Figure 47 Removing a Connector Spring Loosen the remaining screw on the adjacent connector on the power supply side With this connect...

Page 103: ...ving a Connector Pin Lock 15 Use the following procedure to release each wire in the cable assembly from the rail connector a Position yourself so that you can see the pins b Identify the pin location of the wire c Carefully slide the hollow tip of a 0 3 mm mechanical pencil over the outermost pin of the pin pair Then apply a gentle force both toward the other pin in the pin pair and toward the wi...

Page 104: ...osen the two jackpost screws that secure the PEM to WACS cable to the control bulkhead Then remove the PEM to WACS cable from the cabinet 17 If you are replacing a clock to WACS cable use the following procedure to remove the cable connector from the panel behind the I O bulkhead a Swing the I O bulkhead toward you to expose the panel behind it Locate the clock to WACS cable connection Note that y...

Page 105: ...ACS cable from the cabinet Wire Installation 1 Determine the location for the replacement cable 2 Ensure that the rail connector where the cable connects is loose and accessible through the card cage 3 Perform the following steps to insert each of the cable assembly wires in the rail connector a Position the wire above or below in the case of the clock to WACS cable the appropriate pin slot in the...

Page 106: ... 8 Push the connector toward the spring to ensure that the connector moves laterally and then springs back into position 9 Insert the foam plug in each connector slot Ensure that the wires pass through the slit in the middle of the foam 10 Use a 5 mm hex wrench to connect the other end of the cable to the panel behind the I O bulkhead clock to WACS cable or to the control bulkhead PEM to WACS cabl...

Page 107: ... 168 A Cray Research Silicon Graphics Proprietary 107 15 Return the system to operation ensure proper function and close the cabinet doors Figure 51 Inserting and Seating a Plastic Connector Pin Lock Place curve of dental pick between the 2 rows of pins and slide it back and forth ...

Page 108: ... shown Ensure that theplastictiponthewirerodisatthewire insertion end of the connector block and ensure that the slanted portion of the cavity in the plastic tip faces the outside of the connector block Then insert the 2 pin connector into the cavity as shown at left The cavity pinches the pins together as you insert the connector 2 3 4 Pull the rod through the connector block to insert the 2 pin ...

Page 109: ...4 pin P N 15255000 Microprocessor Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s CAUTION Observe all ESD precautions Failure to do so could result in damage to the equipment WARNING Ensure that the electri...

Page 110: ...Carefully insert the tool s extraction tips into the microprocessor s extraction slots Insert the extraction tips as far as possible the tips should touch the back of the microprocessor socket d While you gently press the extraction tips against the back of the microprocessor socket gently squeeze the handles on the extraction tool together until the microprocessor separates from pops free of the ...

Page 111: ...AC Repair and Adjustment Procedures FRP 15 WACS Microprocessor EPROM Replacement HMM 168 A Cray Research Silicon Graphics Proprietary 111 Figure 53 WACS Microprocessor Removal ...

Page 112: ...processor for insertion in the WACS scanner c Align the microprocessor with the microprocessor socket then gently push the microprocessor into the socket If the alignment is correct and you do not feel significant resistance press the flat portion of the microprocessor with you thumb until the microprocessor is fully seated in the socket 2 Close the WACS panel rotate the two latch screws countercl...

Page 113: ... Required Flatblade screwdriver 1 Phillips screwdriver Scanner Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it CAUTION Observe all ESD precautions Failure to do so could result in damage to the equipment WARNING Ensure that the electrical plug for the equipment that ...

Page 114: ...defective scanner 7 Replace the replacement scanner in the ESD protective bag 8 Disconnect the WACS connectors Amp modu connectors from the defective WACS scanner a Pull the side latches away from the connectors as shown in Figure 54 b Pull the connectors with firm even pressure to disconnect them from the WACS scanner c Move the connectors to the side Figure 54 WACS Scanner Connector 9 Remove the...

Page 115: ...ht angle 5 with the socket end closer to the floor b Gently press the power strip horizontally into the scanner portion of the power connector Ensure that the sockets align with the pins and that the tabs on the top of the power strip stay on the outside top of the scanner portion of the connector Refer to Figure 55 c Carefully place the fingers of both hands on the back of the scanner PCB to prov...

Page 116: ...air and Adjustment Procedures 116 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 55 Connecting the Power Strip Tab Power Strip Scanner Portion of Power Strip Position the Power Strip Press Together Step 4a Step 4b Step 4c Seat Fully ...

Page 117: ...0 module assembly disk IOSF display Tools Required 7 mm wrench 1 Phillips screwdriver Display Removal 1 Open the front cabinet door 2 Open the WACS panel and locate the display board 3 Disconnect the WACS connector Amp modu connector from the defective WACS display WARNING Live voltage is present in the cabinet during this procedure Failure to avoid live power components could result in severe sho...

Page 118: ...ssure to disconnect it from the WACS scanner c Move the connector to the side Figure 56 WACS Display Connector 4 Use a 7 mm wrench to remove the 4 nuts and washers that hold the display frame to the WACS panel then remove the WACS frame and display from the cabinet Refer to Figure 57 5 Use a 1 Phillips screwdriver to remove the 4 screws that hold the display board to the display frame 6 Remove the...

Page 119: ... the display frame with the 4 screws that you removed earlier 3 Secure the display frame and display module to the WACS panel with the 4 nuts and washers you removed earlier 4 Connect the WACS display connector push the connector horizontally into the display portion of the connector until the side latches snap into place 5 Close the WACS panel 6 Ensure that the display operates properly 7 Close t...

Page 120: ...edlenose pliers optional for wire removal Switch Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the WACS panel 4 Record the locations of the wires that connect to the switch NOTE You will leave the ...

Page 121: ...itch from the cutout in the WACS panel Switch Installation 1 Carefully move the wires from the defective switch to the replacement switch one wire at a time Then set the defective switch aside You may want to use a pair of needlenose pliers to assist you in removing the wires from the defective switch 2 After you install the wires on the replacement switch push the switch through the cutout in the...

Page 122: ...cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the WACS panel 4 Use a 2 Phillips screwdriver to remove the panel that covers the blower controller SCR1 Four screws hold the panel in place 5 Use a small flatblade screwdriver to depress the top flan...

Page 123: ...et 8 Mark the switch to identify it as defective Switch Installation 1 Carefully move the wires from the defective switch to the replacement switch one wire at a time Then set the defective switch aside 2 After you install the wires on the replacement switch push the switch through the cutout in the WACS box until it locks in place 3 Replace the panel that covers the blower controller SCR1 Four 2 ...

Page 124: ...the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the EMI filter from the back of the front door Use the 6 mm wrench to remove the 8 hex screws that attach the EMI filter to the door 4 Use a 2 Phillips screwdriver to remove the aesthetic panel ...

Page 125: ...h the switch out the front of the door Switch Installation 1 Push the switch through the opening in the switch box until the flanges lock the switch in place 2 Connect the switch wires 3 Replace the switch box 4 Apply power to the cabinet and check the switch function 5 Replace the aesthetic panel and the EMI filter 6 Close the front door 7 Return the cabinet to operation CAUTION The edges of the ...

Page 126: ...ock switch board Tools Required Small flatblade screwdriver 1 Phillips screwdriver 7 mm wrench Switch Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it CAUTION Observe all ESD precautions Failure to do so could result in damage to the equipment WARNING Ensure that the ...

Page 127: ...k switch board Two screws secure the cable connector to the board 5 Remove the switch cover plate from the cabinet Four 1 Phillips screws with washers secure the cover plate to the blower exhaust shield The screw heads are visible on the blower exhaust shield as shown in Figure 60 6 Use a 7 mm wrench to remove the 4 nuts that hold the switch board to the blower exhaust shield 7 Remove the switch b...

Page 128: ...route the switches through the switch cutouts in the blower exhaust shield b Secure the switch board with the four 7 mm nuts one per switch 2 Replace the switch cover plate and secure it with the four 1 Phillips screws and washers 3 Connect the cable to the clock switch board and tighten the 2 retaining screws with a small flatblade screwdriver 4 Return the cabinet to operation check the switch fu...

Page 129: ...er it is a good safety practice to do so Part Number 15130000 thermistor assembly module temperature Tools Required 4 mm hex allen wrench Thermistor Removal 1 Identify the defective thermistor 2 Remove the module from the cabinet using FRP 5 3 Set the module heat sink down on an ESD safe surface WARNING Live voltage is present in the cabinet during this procedure Failure to avoid live power compon...

Page 130: ...r from the module s thermistor connector Refer to Figure 61 The miniconnector does not contain a latch just pull it straight out toward the module handle Figure 61 Module Thermistor 5 Use the 4 mm hex wrench to remove the allen screw that secures the thermistor to the PCB 6 Remove the thermistor from the module Thermistor Connector Handle End Power End of PCB of PCB Allen Screw ...

Page 131: ...tion 1 Position the replacement thermistor on the PCB and insert the allen screw through the thermistor and into the PCB Tighten the screw finger tight 2 Plug the 2 pin miniconnector into the thermistor connector 3 Install the module in the cabinet refer to FRP 5 4 Return the cabinet to operation check thermistor function and close the cabinet doors ...

Page 132: ...sary apply heat to the each thermistor for example apply body heat with your hand and check the WACS display to determine which thermistor is defective 3 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 4 Use a 1 Phillips screwdriver to remove the...

Page 133: ... flanges and push the connector out of the connector bracket Figure 62 Releasing the Thermistor Connector from the WACS Harness 6 Use the following technique to remove the 2 pin miniconnector from the thermistor connector as shown in Figure 63 Carefully use a small flatblade screwdriver to pry the connector lock on the wire end of the thermistor connector so that it releases the miniconnector At t...

Page 134: ... the replacement thermistor through the wire cutout in the panel 2 Plug the 2 pin miniconnector into the thermistor connector Insertion may be difficult To improve alignment it may be helpful to pull the other miniconnector partially out of the thermistor connector 3 If you removed the connector from the connector bracket reinstall it by pushing it into the bracket until the side flanges lock in p...

Page 135: ...e cabinet and test the thermistor as follows With the WACS on and the blower and power supplies off check the temperatures on the WACS display Then apply heat to the new thermistor for example apply body heat with your hand and check the temperature change on the WACS display 7 Replace the panel return the cabinet to operation and close the door ...

Page 136: ...nbefore you perform this procedure Part Number 57199600 thermistor assembly air flow Tools Required 1 and 2 Phillips screwdrivers Small flatblade screwdriver Heat gun optional Thermistor Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it WARNING Open the cabinet s main ...

Page 137: ...ewdriver to remove the module panel Eight 1 4 turn screws hold the panel in place e Use a 1 Phillips screwdriver to remove the upper plenum panel Six screws hold the panel in place 4 Press the release lever usually on the power supply side of the connector and pull the wire from the WACS harness up to disconnect the thermistor connector from the WACS harness Refer to Figure 64 5 Remove the four 2 ...

Page 138: ...Silicon Graphics Proprietary HMM 168 A Figure 64 Releasing the Thermistor Connector Figure 65 Exhaust Air Thermistors Release Lever Side Flanges Step 4 Step 7 From WACS Harness Thermistor Connector Primary Thermistor Thermistor Connector Screw View from Top View from Cabinet Rear Thermistor Plate ...

Page 139: ... connector lock on the wire end of the thermistor connector so that it releases the miniconnector At the same time gently pull the miniconnector out Refer to Figure 66 9 Remove the defective thermistor from the thermistor plate One 2 Phillips screw holds each thermistor in place Figure 66 Releasing the Miniconnector Thermistor Installation 1 Secure the new thermistor to the sensor plate with a 2 P...

Page 140: ...vides normal readings b If a heat gun is available use it to apply heat to the new thermistor and check the temperature change on the WACS display 8 Remove power from the cabinet 9 Replace the upper plenum panel and the module panel 10 Replace the blower exhaust shield and attach the cable to the clock switch board 11 Return the cabinet to normal operation and close both cabinet doors WARNING Ensu...

Page 141: ... CB1 is open before you perform this procedure Part Number 57199700 thermostat 65 degree C Tools Required 1 and 2 Phillips screwdrivers Multimeter ohmmeter Heat gun optional Thermostat Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it WARNING Open the cabinet s main di...

Page 142: ... turn screws hold the panel in place e Use a 1 Phillips screwdriver to remove the upper plenum panel Six screws hold the panel in place 4 Remove the four 2 Phillips screws that hold the thermistor thermostat plate The thermistor wires and thermostat wires will support the plate 5 Determine the location of the defective thermostat Use an ohmmeter to test the thermostats if necessary 6 Disconnect th...

Page 143: ...rmostat and wires with an ohmmeter 5 If a heat gun is not available Open the power supply circuit breakers CB2 through CB7 and blower circuit breaker CB8 then close the main disconnect circuit breaker CB1 and the WACS circuit breaker CB9 Ensure that CB1 does not trip open 6 If a heat gun is available a Have a partner watch the exhaust air temperatures on the WACS display while you use a heat gun t...

Page 144: ...rmistors c Allow the thermostat to cool to less than 100 F 38 C then reset CB1 7 Replace the upper plenum panel and the module panel 8 Replace the blower shield and connect the cable to the clock switch board 9 Return the cabinet to normal operation and close both cabinet doors WARNING The thermostats receive line voltage Do not contact them Failure to avoid the thermostats and thermostat wires co...

Page 145: ...front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the WACS circuit breaker CB9 4 Open the WACS panel and locate the defective scanner fuse WARNING Ensure that the electrical plug for the equipment that you service is unp...

Page 146: ... required specifications 8 Replace the protective fuse cover 9 Open the module power supply circuit breakers CB2 through CB7 and close the WACS panel 10 Close the main disconnect circuit breaker CB1 and the WACS circuit breaker CB9 then verify that the fuse does not blow and that the WACS board appears to function The WACS display is driven by scanner A and the SWS NWACS display is driven by scann...

Page 147: ...ement HMM 168 A Cray Research Silicon Graphics Proprietary 147 11 If the fuse blows again troubleshoot a possible power problem If the input power to the scanner is acceptable replace the WACS scanner 12 Restore the cabinet to operation and close the front cabinet door ...

Page 148: ... Fuse Replacement 1 Open the front cabinet door 2 Identify the failed module power supply 3 Open the circuit breaker for that module power supply and disconnect the power cord where it plugs into the power supply 4 Remove the fuses one at a time and check for continuity with an ohmmeter Use a flatblade screwdriver to remove the fuse and fuse cap Figure 69 shows the locations of the fuses 5 Install...

Page 149: ...Supply Fuse Replacement HMM 168 A Cray Research Silicon Graphics Proprietary 149 Figure 69 Power Supply Fuses 7 Check the WACS display to ensure a proper power supply output 8 Restore the cabinet to operation and close the front cabinet door Fuse Caps ...

Page 150: ...r Multimeter ohmmeter Fuse Replacement 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the blower circuit breaker CB8 4 Open the WACS panel 5 Remove the fuses one at a time and check for continuity with an o...

Page 151: ...ired specifications 7 Close the WACS panel 8 Plug in the cabinet close the main disconnect circuit breaker CB1 the blower circuit breaker CB8 and the WACS circuit breaker CB9 and check blower function 9 Restore the cabinet to operation and close the front cabinet door 10 Periodically check the cabinet and module temperatures to ensure proper blower speed control Figure 70 Blower Control Fuse Locat...

Page 152: ...V Tools Required 2 Phillips screwdriver Small flatblade screwdriver Circuit Breaker Removal 1 Open the cabinet s front door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it WARNING Remove all power from the cabinet Failure to do so could result in damage to the equipment and serious injury or death to the...

Page 153: ... Use the 2 Phillips screwdriver to remove the input line wires and input shunt trip wire from CB1 The input wires are located on the module side of CB1 NOTE The Ferrules used on the wires sometimes get stuck in the breaker wire cage Use care to avoid this 7 Remove the circuit breaker from the DIN rail a Insert a small flatblade screwdriver into the slot in the left spring latch b Using the bottom ...

Page 154: ...FRP 29 Main Disconnect Circuit Breaker CB1 Replacement AC Repair and Adjustment Procedures 154 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 71 Removing CB1 Step 7 ...

Page 155: ... DIN rail b Use the flatblade screwdriver to open the spring latches as you rotate the circuit breaker down onto the DIN rail 4 Refer to your record of the wire locations while you insert the input line wires into the module side of the circuit breaker Hold the breaker firmly as you tighten the screw clamps securely 5 Ensure that all screw clamps on CB1 are tight 6 Position the circuit breaker so ...

Page 156: ...er 2 Phillips screwdriver Small flatblade screwdriver Circuit Breaker Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the WACS panel 4 Note the positions of the wires that connect to the defective ci...

Page 157: ...flatblade screwdriver into the slot in the spring latch which is located on the bottom of the circuit breaker b Using the bottom of the circuit breaker as a fulcrum lift the screwdriver handle to press the spring latch downward c Hold the spring latch in this disengaged position and rotate the lower portion of the circuit breaker up and out of the DIN rail d Now lift the top portion of the circuit...

Page 158: ...e 72 Removing the CB8 CB9 and CB10 Circuit Breakers from the WACS Box Circuit Breaker Installation 1 Ensure that the screw clamps wire cages in the replacement circuit breaker are open 2 Refer to your record of the wire locations while you insert the wires into the top of the circuit breaker Hold the breaker firmly and tighten the screw clamps securely Step 6 ...

Page 159: ...ch then rotate the circuit breaker into place and release the spring latch 4 Refer to your record of the wire locations while you insert the wires into the bottom of the circuit breaker Hold the breaker firmly and tighten the screw clamps securely 5 Ensure that all screw clamps on the circuit breaker are tight 6 Position the circuit breaker so that it aligns with the hole in the WACS panel then cl...

Page 160: ...ewdriver Small flatblade screwdriver Circuit Breaker Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the air filter Refer to FRP 37 for removal instructions WARNING Ensure that the electrical plug ...

Page 161: ... to the defective circuit breaker 6 Use a 2 Phillips screwdriver to remove the output wires from the bottom of the defective circuit breaker 7 Remove the circuit breaker from the DIN rail a Insert a small flatblade screwdriver into the slot in the spring latch which is located on the bottom of the circuit breaker b Using the bottom of the circuit breaker as a fulcrum lift the screwdriver handle to...

Page 162: ...iver to open the screw clamps wire cages in the replacement circuit breaker 2 Insert the output wires into the top of the circuit breaker Hold the breaker firmly and tighten the screw clamps securely 3 Insert the circuit breaker in the DIN rail a Insert the upper portion of the circuit breaker into the DIN rail b Use the flatblade screwdriver to open the spring latch then rotate the circuit breake...

Page 163: ...nto the bottom of the circuit breaker Hold the breaker firmly and tighten the screw clamps securely 5 Ensure that all screw clamps on the circuit breaker are tight 6 Position the circuit breaker appropriately then replace the breaker box cover and secure it with screws and washers 7 Replace the air filter 8 Return the system to operation and close the front cabinet door ...

Page 164: ...ver Multimeter ohmmeter Switch Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the air filter to provide greater access to the power box Refer to FRP 37 for removal instructions 4 Remove the cover ...

Page 165: ...k the list for accuracy 6 Use a large Phillips or flatblade screwdriver to remove the wires It may be helpful to loosen the switch refer to Step 7 before you remove all of the wires 7 Use a 2 Phillips screwdriver to remove the screws that secure the switch to the bottom of the power box 8 Remove the switch 9 If necessary remove the jumpers from the back of the old switch and install them in the sa...

Page 166: ...r box 3 Read the following notes then connect the switch wires NOTE Ensure that you connect all wires to the correct locations Refer to your list of wire locations while you connect the wires Then double check your work when complete Tighten the connections securely but be careful not to strip the screws For terminals that connect to two wires install wires as shown in Figure 75 Figure 75 Two wire...

Page 167: ...er box with the 4 screws 5 Ensure that the switch is set for the proper voltage 6 Use a multimeter to test the connections You may refer to the list of connections that you created before you removed the defective switch and or to a schematic as you test the connections 7 Replace the power box cover 8 Close the front door of the cabinet 9 Return the cabinet to operation ...

Page 168: ...main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the air filter to provide greater access to the power box Refer to FRP 37 for removal instructions 4 Remove the cover from the power box a Use a 2 Phillips screwdriver to remove the screws that hold the cover...

Page 169: ...er some cabinets may require a 2 5 mm hex driver to remove the screws that hold the relay to the bottom of the power box then remove the relay Figure 76 Time delay Relay Location Installation 1 Set the replacement relay to match the settings on the defective relay 2 Secure the replacement relay in the power box with the Phillips or hex screws 3 Connect the wires to the relay Refer to your notes fo...

Page 170: ...disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the air filter to provide greater access to the power box Refer to FRP 37 for removal instructions 4 Remove the cover from the power box a Use a 2 Phillips screwdriver to remove the screws that hold the cover in p...

Page 171: ...ct to FL1 6 Use a 3 8 in wrench to disconnect the wire lugs and wires from both ends of FL1 7 Remove FL1 from the power box On the left side of FL1 two 7 mm nuts secure FL1 to the bottom of the power box On the right side of FL1 four 3 8 in nuts secure FL1 to a vertical panel Figure 77 Line Filter Location WARNING The line filter is heavy and difficult to reach remove it carefully Support and prot...

Page 172: ...notes for the correct locations Securely tighten the wires but be careful not to overtighten them which may break the studs If possible use a thin 3 8 in wrench to hold the inside nut while you tighten the outside nut of each stud Double check the wiring Ensure that none of the ring tongue terminals touch adjacent terminals or wires 3 Replace the power box cover and the air filter 4 Restore the ca...

Page 173: ...onnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Remove the air filter to provide greater access to the power box Refer to FRP 37 for removal instructions 4 Remove the cover from the power box a Use a 2 Phillips screwdriver to remove the screws that hold the cover in place...

Page 174: ...connect to the front of the contactor and remove the wires with a medium flatblade screwdriver 6 Remove the two 7 mm nuts that hold the contactor to studs on the floor of the power box 7 Pull the contactor forward so that you can access the wires on the back of the contactor then record the locations of the wires that connect to the back of the contactor 8 Remove the wires with a medium flatblade ...

Page 175: ...e of the contactor Refer to your notes for the correct locations 2 Secure the contactor to the studs on the floor of the power box with the two 7 mm nuts 3 Connect the wires to the front power supply side of the contactor Refer to your notes for the correct locations 4 Replace the power box cover and the air filter 5 Restore the system to operation and close the front cabinet door ...

Page 176: ...resistor described here make the necessary modifications to this procedure to ensure a safe and successful replacement Part Number 57185400 resistor 50W 330 Ohm Tools Required 2 Phillips screwdriver 1 Phillips screwdriver Medium flatblade screwdriver Wire cutters Heat gun and solder sleeves or soldering iron and solder Heat shrink or electrical tape R1 Removal 1 Open the front cabinet door 2 Open ...

Page 177: ... 2 Phillips screwdriver to remove the screws that hold the cover in place b Pull the cover straight up then remove it from the cabinet Be careful not to damage the inlet air thermistors or the EMI gasket on the bottom of the cover 5 Use wire cutters to cut the 2 wires that connect to R1 Cut the wires as close as possible to R1 6 Use a 1 Phillips screwdriver to remove the 2 screws that secure R1 to...

Page 178: ...ement resistor R1 in the power box with the 2 Phillips screws 2 Use the following steps to attach each wire to R1 a Strip and clean the ends of the wire b Slide heat shrink onto the wires c Insert the wire in a solder sleeve d Connect the solder sleeve with wire to R1 e Heat the solder sleeve with the heat gun f Place the heat shrink over the solder sleeve and shrink the heat shrink 3 Replace the ...

Page 179: ...annot use the following procedure then you must remove the old filter before you insert the new filter Part Number 57188100 filter air intake Tools Required Small flatblade screwdriver Flashlight Filter Replacement 1 Open the front cabinet door 2 Use the screwdriver to loosen the retaining screw on the front end of one filter bracket 3 Rotate the filter bracket 90 toward the center of the cabinet ...

Page 180: ...ntime with the customer With the system down you can tie wrap all loose torus and GigaRing cables so that they do not touch the filter 6 If no cables touch the filter position the replacement filter the airflow direction is marked on the narrow end and slide it into the cabinet above the old filter Refer to Figure 81 7 Pull the old filter from the cabinet The new filter should catch debris that fa...

Page 181: ...AC Repair and Adjustment Procedures FRP 37 Air Filter Replacement HMM 168 A Cray Research Silicon Graphics Proprietary 181 Figure 81 Filter Replacement New Filter Old Filter Step 6 ...

Page 182: ...rewdriver 4 mm hex allen wrench with hex driver and extension Flashlight Blower Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the rear cabinet door 4 Use a small flatblade screwdriver to disconnect...

Page 183: ...cabinet A slotted thumb screw secures the panel at each corner of the cabinet 8 Loosen the 2 thumb slot screws and 2 wedges that secure the blower assembly in the cabinet Refer to Figure 82 and Figure 83 a Use a flatblade screwdriver to loosen the thumb slot screws that are close to you b Use the hex driver with extension to loosen the 4 mm hex screw on each wedge system The screws and wedges lie ...

Page 184: ...edures 184 Cray Research Silicon Graphics Proprietary HMM 168 A Figure 82 Blower Assembly and Mounting Hardware Thumb Screws 2 Slide Rails blower assembly slides on these rails Wedge System under mounting hardware See Figure 83 Bottom View Top View Blower Connector ...

Page 185: ... remove the blower from the cabinet WARNING The blower weighs approximately 40 lbs Remove the blower carefully Ensure that a second person is available to help you remove the blower It is heavy and may cause back injury or it may cause injury if it falls on someone Hex Screw Runs length of wedge system Retaining Nut As you tighten the nut the wedges rise and lock the blower in place Front End Back...

Page 186: ...s to you and your assistant Blower Replacement 1 Install the replacement blower in the cabinet a With the help of another person lift the blower into position then insert it horizontally into the rear of the cabinet b Position the blower on the slide rails then slide the blower into its operating position 2 Secure the blower with the two thumb slot screws and the two wedge systems 3 Connect the bl...

Page 187: ...net door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the blower circuit breaker CB8 4 Access SCR1 a Open the WACS panel b Remove the panel that covers the blower controller SCR1 Refer to Figure 84 WARNING Ensure that the electrical p...

Page 188: ...he locations of the power wires that connect to the bottom of SCR1 b Use tie straps to bundle and separate the two groups of wires that connect to the screws power lugs on the bottom of SCR1 c Use a large flatblade screwdriver to loosen the screws power lugs that secure the wires to SCR1 Refer to Figure 85 d Remove the wire s and move them out of the way Remove the power terminals from SCR1 a Use ...

Page 189: ...s Proprietary 189 7 Use a 2 Phillips screwdriver to loosen the 2 left screws that hold SCR1 to the rear wall and remove the 2 right screws Slide SCR1 to the right until it clears the screws and remove SCR1 from the cabinet Figure 85 Removing the Power Wires from SCR1 Power Connection Screws Lugs Pluggable Connections ...

Page 190: ... 2 Secure the replacement SCR1 to the rear wall with the 4 Phillips screws 3 Connect all wires and connections to SCR1 Refer to your notes for the correct locations 4 Return the cabinet to operation and check blower function 5 Remove power from the cabinet again then replace the panel that covers the blower controller SCR1 6 Close the WACS panel then return the cabinet to operation 7 Close the fro...

Page 191: ...r power SCR 20A with transformer Tools Required 2 Phillips screwdriver 1 Phillips screwdriver Transformer Removal 1 Open the cabinet s front door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the blower circuit breaker CB8 WARNING Ensu...

Page 192: ...oller SCR1 5 Record the locations of the wires that connect to the transformer then disconnect them Refer to Figure 87 Figure 87 Transformer T1 6 Remove the transformer from the cabinet Two 1 Phillips screws hold the transformer to the side wall NOTE It may be necessary to loosen or remove the blower controller SCR1 to provide access to the screw on the far side of the transformer Refer to FRP 39 ...

Page 193: ...ormer to the side wall with the 2 Phillips screws 2 Connect the wires to the transformer Refer to your notes for the correct locations 3 Return the cabinet to operation and check blower function 4 Remove power from the cabinet again then replace the panel that covers the blower controller SCR1 5 Close the WACS panel then return the cabinet to operation 6 Close the front cabinet door ...

Page 194: ...llips screwdriver Wire cutters 13 mm open end box wrench Heat gun and solder sleeves or soldering iron and solder Heat shrink or electrical tape C1 Removal 1 Open the front cabinet door 2 Open the cabinet s main disconnect circuit breaker CB1 and unplug the cabinet Place a lockout device over the cabinet s plug and lock tag it You may also open lock and tag the customer s wall breaker s 3 Open the...

Page 195: ...e blower controller SCR1 5 Label the wires that connect to the run capacitor then cut the wires at the wire splice It also may be necessary to cut the wire ties that hold the wires 6 Use the 13 mm wrench to remove the nut that secures the run capacitor Then remove the capacitor Figure 88 Run Capacitor C1 Retaining Nut Located on bottom of capacitor Capacitor Panel Wires to C1 Wire splices are not ...

Page 196: ...itor and secure it with the nut 2 Solder each connection to the capacitor a Strip and clean the ends of the wires that you will connect b Slide heat shrink onto a wire c Insert the wires in a solder sleeve d Heat the solder sleeve with the heat gun e Place the heat shrink over the solder sleeve and shrink the heat shrink 3 Return the cabinet to operation and check blower function 4 Remove power fr...

Page 197: ...se or soak them in water Allow the filters to dry completely before you install them in the cabinet Do not use alcohol or strong solvents to clean the filters Adjusting the Module Power Supply Output Voltage At present the modules should receive between 3 1 Vdc and 3 5 Vdc from the module power supplies To adjust the output of an individual power supply 1 Open the front cabinet door 2 While you or...

Page 198: ...FRP 41 Run Capacitor C1 Replacement AC Repair and Adjustment Procedures 198 Cray Research Silicon Graphics Proprietary HMM 168 A ...

Page 199: ...AC Repair and Adjustment Procedures FRP 41 Run Capacitor C1 Replacement HMM 168 A Cray Research Silicon Graphics Proprietary 199 ...

Page 200: ...FRP 41 Run Capacitor C1 Replacement AC Repair and Adjustment Procedures 200 Cray Research Silicon Graphics Proprietary HMM 168 A ...

Page 201: ...ard replacement WACS 113 Boundary scan wire replacement 87 C Cabinet overview 11 Cabinet power switch SW2 replacement 124 Cables boundary scan wire replacement 87 clock replacement 76 GigaRing replacement 71 torus replacement 65 WACS replacement 99 Capacitor replacement 194 CB1 replacement 152 Circuit breaker replacement main CB1 152 power supply 160 WACS panel 156 Clock auxiliary power supply rep...

Page 202: ...r card replacement 42 Display WACS replacement 117 Doors opening 13 removing 14 E Emergency on off switch replacement 124 EMI filter cleaning 197 Enable switch replacement 120 EPROM replacement 109 ESD precautions 4 F Filter AC line replacement 170 air cleaning 197 replacement 179 EMI cleaning 197 FRU list 5 FRU procedures See Procedures Fuse replacement blower 150 power supply 148 WACS 145 ...

Page 203: ...ower supply replacement 21 rail replacement bottom 59 rail replacement top 52 replacement 32 N Numbers FRUs 5 spares 8 tools 9 P Panels removing 16 Part numbers FRUs 5 spares 8 tool kit 9 PM procedures 197 Power See also Power cord Power supplies circuit breaker replacement 160 fuse replacement 148 Power supplies auxiliary clock replacement 29 module replacement 21 rail replacement 49 ...

Page 204: ...wer supply 160 WACS panel 156 contactor replacement 173 daughter card replacement 42 door opening 13 door removal 14 EMI filter cleaning 197 filter replacement air 179 power 170 fuse replacement blower 150 power supply 148 WACS 145 line filter replacement 170 module replacement 32 panel removal side 16 power supply replacement auxiliary 29 module 21 preventive maintenance 197 rail replacement modu...

Page 205: ...S board replacement 113 WACS display replacement 117 WACS EPROM replacement 109 wire and cable replacement boundary scan 87 clock wire 76 GigaRing cable 71 module to WACS cable 99 R Resistor replacement 176 Restart switch replacement 120 Run capacitor replacement 194 S Safety information 4 Scanner replacement 113 SCR1 replacement 187 Skin trim removal 16 Spares list 8 SW1 replacement 164 Switches ...

Page 206: ... list 9 Torus cables replacement 65 Transformer replacement 191 Trim removal 16 V Voltage adjustment 197 Voltage selector switch SW1 replacement 164 W WACS board replacement 113 cable replacement 99 display replacement 117 EPROM replacement 109 fuse replacement 145 switch replacement 120 thermistor replacement inlet air 132 module 129 outlet air 136 thermostat replacement 141 ...

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