Sun External I/O Expansion Unit
 
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In this Document

Goal

Solution

Oracle Confidential INTERNAL - Do not distribute to customer (OracleConfidential).
Reason: This part is a FRU

Applies to:

Goal

How to remove and replace the Chassis Assembly of an External I/O Expansion Unit

Solution

DISPATCH INSTRUCTIONS
- WHAT SKILLS DOES THE ENGINEER NEED:
Engineer has to complete the host system's (Mx000/T5xxx) training.

- TIME ESTIMATE:
120 minutes

- TASK COMPLEXITY:
3 = product trained resource required for low complexity product

FIELD ENGINEER INSTRUCTIONS:
- PROBLEM OVERVIEW
How to remove and replace the Chassis Assembly of an External I/O Expansion Unit

- WHAT STATE SHOULD THE SYSTEM BE IN TO BE READY TO PERFORM THE
RESOLUTION ACTIVITY?
For Mx000 systems the links to the External I/O Expansion Unit must be powered down if the domains are up and running.
    Power down the links by disconnecting the server IOU slot:
    # cfgadm -c disconnect ap_id...
     Where ap_id are the server IOU slots that are connected to the External I/O Expansion Unit.

For T5xxx systems or a cold replacement on Mx0000 stop the domains that are connected to the I/O boat.
    For information about stopping a domain, refer to the documentation for the server.

- WHAT ACTION DOES THE ENGINEER NEED TO TAKE:
In this procedure, the following parts are moved from the old chassis to the replacement chassis:
   * Front bezel
   * I/O boat(s)
   * PSUs

A) Locating the New System Serial Number Label

The replacement chassis has a new system serial number. This serial number label is located inside the left I/O boat bay.
In the following procedure, new serial number labels will be attached to the old bezel, and the old bezel will be used with the new chassis.
New system serial number labels are not provided for the top cover. The old top cover will not be used on the new chassis.

B) Preparing the External I/O Expansion Unit

1. Use an antistatic strap for this procedure.

2. Unpack the replacement chassis and place it on an antistatic work space.
   NOTE: Use an antistatic work space that is wide enough to accommodate two External I/O Expansion Units side by side (40 in./1000 mm).

3. Verify the links to the External I/O Expansion Unit are powered off.
  
4. Turn off the AC switches on both PSUs at the front of the External I/O Expansion Unit.

5. At the rear of the External I/O Expansion Unit, disconnect the AC cords from the internal AC cables.

6. Move the cable plate to the service position:
   a. Loosen the cable plate locking screw(s).
   b. Pull the cable plate toward you approximately 0.5 in./13 mm, then raise it approximately 0.75 in./20 mm, until the bottom of the plate is above the tops of the support brackets.
   c. Push the cable plate forward to its service position so that the cable plate rests on the support brackets.
      The tabs on the sides of the cable plate should lie in the small notches on the tops of the support brackets.

7. Label all I/O cables.

8. Disconnect the link cable from the link card in slot 0 in each I/O boat

9. Disconnect all I/O cables from the PCI cards in the External I/O Expansion Unit.

10. Remove the I/O boat(s) from the original External I/O Expansion Unit:
   a. Loosen the two captive screws located at the top of the I/O boat.
   b. Pull the I/O boat out of the chassis approximately 6 in./150 mm.
   c. Support the bottom of the I/O boat with one hand, then pull the boat out of the slot.
   d. Set the I/O boat flat on an antistatic surface.
      CAUTION! Do not rest an I/O boat vertically. The plastic electrical connector on the back is breakable.
   e. Note which boat is boat 0 and which is boat 1 so that they will go in the same slots in the replacement chassis.
   f. Label the boats.

11. Remove the PSUs from the front of the External I/O Expansion Unit:
   a. Loosen the handle locking screw on the PSU handle.
   b. Unlock the PSU by pulling it out 90 degrees.
   c. Pull the PSU out approximately 6 in./150 mm and stop.
      CAUTION! The PSU is heavy (7.5 lb/3.4 kg).
      When you can see the warning label on the top of the PSU, the PSU is almost fully out of the PSU slot.
      CAUTION! Do not allow the rear of the PSU to drop. The connector at the rear of the PSU can be damaged if it strikes the edge of the slot.
   d. Support the bottom of the PSU with one hand, and pull the PSU out of the External I/O Expansion Unit.
   e. Set the PSU flat on an antistatic surface.
      CAUTION! Do not rest a PSU vertically. The plastic electrical connector on the back is breakable.

12. Remove the External I/O Expansion Unit chassis from the rack.
   a. Use a No. 2 Phillips screwdriver to remove the four mounting screws from the front of the chassis.
   b. Pull the chassis out of the rack and place it on an antistatic workbench.
      The empty chassis weighs 30 lb (13.6 kg).

C) Moving the Bezel to the New Chassis

1. Use an antistatic strap for this procedure.

2. Remove the bezel from the old chassis:
   a. Use a No. 1 Phillips screwdriver to remove the top cover.
      There are 14 screws on the cover:
      * 2 screws on the right side
      * 2 screws on the left side
      * 10 screws on the top
      Note that the top cover of the old chassis can be identified by the presence of service labels. The top cover of the new chassis does not have service labels.
   b. Set the cover aside.
   c. Use a No. 1 Phillips screwdriver to remove 4 screws from the top of the bezel, then tilt the top of the bezel away from the External I/O Expansion Unit and lift it off.

3. Install new serial number labels on the bezel.
   The current serial number labels are located at the left PSU opening of the bezel

4. Use a No. 1 Phillips screwdriver to remove the top cover from the new chassis.

5. Set the cover aside.
   This cover will be used with the new chassis.
   NOTE: Do not attempt to move the service labels from the old cover to the new cover. The new cover will be used without service labels.

6. Install the bezel on the replacement External I/O Expansion Unit chassis:
   a. Tilt the bezel away from the External I/O Expansion Unit approximately 10 degrees.
   b. Place the bottom edge of the bezel under the front of the chassis.
      The lugs on the bottom of the chassis front fit into the slots in the bezel.
   c. Tilt the bezel upright and use 4 No. 1 Phillips screws to attach the top of the bezel to the replacement chassis.

7. Install the new top cover on the replacement External I/O Expansion Unit chassis.
   NOTE: The new top cover does not have system serial number label. The new system serial number is located only on labels on the bezel and inside the left I/O boat bay of the FRU chassis.
   Install 10 No. 1 Phillips screws on the top.
   Install 2 No. 1 Phillips screws on each side.

8. Install the old top cover on the old chassis.

D) Installing the External I/O Expansion Unit in the Rack

1. Use an antistatic strap for this procedure.

2. Use a No. 2 Phillips screwdriver to remove the left and right chassis lock brackets from the sides of the old chassis.

3. Set the old chassis aside for return or proper disposal.

4. Install the chassis lock brackets on the sides of the replacement chassis.

5. Slide the replacement chassis into the rack and lock the chassis in place, using two No. 2 Phillips screws for each of the chassis lock brackets.

6. At the front of the chassis, install the PSUs:
   a. Pull the PSU handle to the unlocked position.
   b. Slide the PSU into the slot until the rear of the PSU contacts the centerplane.
   c. Turn the PSU handle into the locked position.
   d. Tighten the handle locking screw on the handle.
   e. Verify that the AC switches are in the Off position.

7. At the rear of the chassis, install the I/O boats.
   a. Carefully slide I/O boat 0 into slot 0.
      Lift the I/O cables out of the way as necessary.
   b. Lock the I/O boat in place by tightening the two screws at the top corners of the I/O boat.
   c. Install I/O boat 1 in the same manner.

8. Lower the cable plate from the service position to the normal position

9. Attach the I/O cables to the PCI cards.

10. For each I/O boat, attach the link cable(s) to the link card in the boat.
   For an optical link card, there are two connections. Insert the TX cable into the link card port marked "TX" and insert the RX cable into the port marked "RX".
   For a copper link card, there is a single connection.

11. Connect AC cords to the internal AC cables on the External I/O Expansion Unit.

OBTAIN CUSTOMER ACCEPTANCE
- WHAT ACTION DOES THE CUSTOMER NEED TO TAKE TO RETURN THE SYSTEM TO
AN OPERATIONAL STATE:

Turn on the AC switches on the External I/O Expansion Unit PSUs.
   On the PSUs the AC power and DC power LEDs should light.

For Mx000 systems the links must be powered up again if the domains are up and running.
    Power up the links by typing:
    # cfgadm -c configure ap_id...
    Where ap_id are the IOU slots in the host server to which an I/O boat is connected.

For T5xxx systems or a cold replacement on Mx000 start the domains that are connected to the External I/O Expansion Unit.
For information about starting a domain, refer to the documentation for the server.

PARTS NOTE:
541-0314 Chassis Assembly/FRU
541-2555 Chassis Assembly/FRU, Taiwan
541-2997 Chassis Assembly/FRU
541-2998 Chassis Assembly/FRU, Taiwan

REFERENCE INFORMATION:
Please see the respective Service Manual on http://download.oracle.com/docs/cd/E19322-01/index.html

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