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Removing and Replacing Parts: Dell™ PowerVault™ 128T Tape Library User and Service Guide

  Level of Difficulty
  Exploded Views of Replaceable Parts (FRUs)
  Removing and Replacing Cards
  Removing and Replacing Drive Modules
  Removing and Replacing the Transport Assembly
  Removing and Replacing the Motherboard
  Removing and Replacing the Power Supply
  Removing and Replacing the Front Panel Display
  Removing and Replacing a Cosmetic Door
  Upgrading Firmware
  Using a CE Diagnostic Tool

Level of Difficulty

Each replacement procedure is rated on how difficult it is to correctly perform.

• [1] Easiest
• [3] Moderate
• [5] Most Difficult

Exploded Views of Replaceable Parts (FRUs)

The exploded views are categorized into the following sections:

• Front and Back FRUs: These parts are accessed from the front or back of the library and include:
  • Cards
  • Drive
  • External cables (cables, terminator, GBIC)
  • Display (RFI shield, display, and viewing windows)
  • Power supply
• Cosmetic and Sheet Metal FRUs: These parts are primarily accessed on the outside of the library and include:
  • Side panels
  • Top and bottom covers
  • Cosmetic doors and door trays
  • Magazine
  • Lifting straps
  • Standalone feet
  • Transport assembly
• Internal FRUs: This exploded view illustrates parts that are found inside the library.

Figure 1. Exploded View of Front and Back FRUs

Table 1.0 Description of Front and Back FRUs

Cosmetic and Sheet Metal FRUs

Figure 2. Cosmetic and Sheet Metal Exploded View (1 of 2)

Table 2. Description of Cosmetic and Sheet Metal FRUs (1 of 2)

Figure 3. Cosmetic and Sheet Metal FRUs Exploded View (2 of 2)

Table 3. Description of Cosmetic and Sheet Metal FRUs (2 of 2)

Internal FRUs

Figure 4. Exploded View of Internal FRUs (1 of 2)

Table 4. Description of Internal FRUs (1 of 2)

Figure 5. Exploded View of Internal FRUs (2 of 2)

Table 5. Description of Internal FRUs (2 of 2)

Removing and Replacing Cards

Level of Difficulty: [1] Easy

CAUTION: This library contains very sensitive electrical components. It is important to follow the proper procedures to prevent electrostatic discharge (ESD). Use wrist-grounding straps and antistatic mats when removing and replacing cards and major assemblies. Failure to follow proper procedures could lead to intermittent failures or premature hard failure.

CAUTION: The Fibre Channel printed circuit boards may contain a laser system (GBIC or GLM module) that is classified as a "Class I Laser Product" under a US Department of Health and Human Services (DHHS) Radiation Performance standard according to the Radiation Control for Health and Safety Act of 1968 and EN60825-1(+A11) safety of laser products. The compliance statement is located on the module.

Removing a Card

1. Review the LEDs on the back of each card to ensure there is no activity on the card (see "Using Library LEDs to Diagnose Status").
2. For Service Personnel Only: Note the library front panel configuration settings (if you will be replacing the controller card), and power off the library. These settings include:
   • Password
   • Network Access
   • Mailslot
   • Fibre Channel or SCSI IDs
3. Note the library configuration settings (if you will be downloading new firmware), and power off the library.
4. Note how the library is connected and the placement of the card, and then remove all external cables attached to the card.
5. Loosen the two thumbscrews on the card by screwdriver.
6. Remove the card by gently pulling it outward.

Replacing a Card

1. Align the edges of the replacement card with the card slot.
2. Gently push, on the lower portion, of the replacement card and slide it into the library until the card is flush with the library.
3. Tighten the thumbscrews (finger tight).
4. Reconnect external cables.
5. Power on the library.
6. Download new firmware (see "Upgrading Firmware").

   NOTE: If the new card has a different version of firmware than the rest of the library, the library could go into a partial availability state due to a firmware mismatch. When this occurs, the front panel will display Partly Available, and the LED bar beneath the front panel display will be solid amber. This is not an indication of a failure, but indicates that you need to download new library firmware.

7. If installing Fibre Channel or remote management cards for the first time, configure the library from the front panel. See "Configuring the Library for Fibre Channel", or "Using the Remote Management Card."

Figure 6. Library Card Positions

1	Vacant slot
2	Remote Management Card
3	Library Controller Card
4	Fibre Channel Controller

Removing and Replacing Drive Modules

Level of Difficulty: [2] Easy to Moderate

A drive module may be replace in either of the following situations:

• The library is powered off during drive replacement, and the SCSI bus chain is disconnected.
• The library is connected to the host, and the backup software can access the functional drives. Though drives can be replaced without disabling or interrupting most functions of the library, this feature must be supported by the backup software. (If you download new drive firmware, power cycle to activate the new firmware.)

Drive Replacement Overview

These steps are documented in more detail on the following pages.

1. Determine which drive has failed (if you are replacing a failed drive).
2. Unload a tape from the drive, if possible.
3. Take the drive module off-line or power off the library.
4. Remove the drive module.
5. Insert and connect the new drive module.
6. Bring the drive online.

NOTE: If the new drive has a different firmware revision than the drives that are already in the library, the library could go into a partial availability state due to a firmware mismatch. When this occurs, the front panel will partly display Partly Available, and the LED bar beneath the front panel display will be solid amber. Download new drive firmware until all drives have the same firmware revision.

Determining Which Drive Has Failed

If a drive has failed or had an error, the following can happen:

• The icons on the library front panel indicate a drive with an error.
• The LEDs on the drive indicate an error.
• The library attempts to take the drive off-line.
• The host indicates an error.

Unloading a Tape From a Drive

Before replacing a drive, unload any tape from the drive (if applicable).

1. From the Drive and Tape Operations menu, select [Unload Tape from Drive].
2. Use the [-] or [+] keys to select the drive you want to unload.
3. Select [Unload] to move the tape from the drive module to the original slot where the tape was located. The tape is automatically rewound before it is unloaded.
4. If you are unable to unload a tape from a failed drive, follow the procedure below.

Taking a Drive Off-line

Although a drive module can be removed without powering off the library, you must first take the drive module off-line. The backup software must support online drive repair. This process may be accomplished by using the library's front panel and following these steps:

1. Check the drive icons on the front panel display to see if the drive has already been taken off-line. Verify the drive module's status by checking the LEDs on the back of the drive module (see Figure 7 "Drive Module LEDs").

   NOTE: If there are no LEDs illuminated on the drive, take the library off-line. Check with the system administrator before powering off the library.

2. If the drive module is not already off-line, go to the Service or Administration and then Online Drive Repair menus. Set the failing drive to off-line state. The drive will automatically attempt to rewind any loaded tape.
3. Select the drive with the [-] or [+] keys, and press [OK].
4. Select [Put Drive Off-line.]. The front panel indicates the success or failure of this operation.

Figure 7. Drive Module LEDs

1) Yellow	2) Green	Description
Off	On	Drive is online and available.
Flashing	Off	Drive is off-line and may be replaced.
On	Flashing	Drive is being brought online.
Flashing	On	Drive is off-line Internal communication has been lost.
On	On	Drive module controller is in reset.
On	Off	Power-on test in progress.
Flashes	Off	Drive module failed power-on test.

Removing a Drive Module

NOTE: To preserve SCSI communications, do not loosen or remove the SCSI cable(s) connected to the outside of the drive module. The connection to be removed is located inside the drive module.

When the drive module has been successfully taken off-line, one of the LEDs on the back of the drive will be flashing yellow. Remove the drive module using the steps below:

1. Verify the external SCSI cable is securely attached to the connector plate.
2. Loosen the thumbscrews on each side of the connector plate, located in the middle of the drive module. If this is your first time loosening the thumbscrews, you may need to use a screwdriver.
3. Gently remove the connector plate, with SCSI cable(s) still connected.
   
   

   Caution: Use standard precautions for electrostatic discharge (ESD) protection.

   
   
4. Grasp the ribbon cable that is plugged into the drive module. Remove the cable by pulling the connector to the left. See Figure 8 "Ribbon Cable and Connector" for the location of the ribbon cable and connector.

Figure 8. Ribbon Cable and Connector

5. Lay the connector assembly to the side, allowing the external cables to hang from the connection(s). Do not disconnect external cables from the connector plate.
6. Loosen the top and bottom thumbscrews on the drive module (see Figure 9 "Removing a Drive").
7. Using the handle that is mounted on the back of the drive module, pull the drive module straight out with one hand while supporting the bottom of the drive module with the other hand.

CAUTION: As the drive module is pulled out, support the bottom of the drive module to avoid dropping or damaging it.

WARNING: To avoid injury, do not insert your hand or foreign objects through the empty drive bay.

Figure 9. Removing a Drive

Installing a Drive Module

1. Hold the drive module with one hand on the drive module handle, while the other hand supports the bottom (see Figure 10 "Installing a Drive Module").
2. Install the drive by inserting the rail at the top of the drive module into the slot at the top of the drive module opening.

NOTE: More force will be required in the last half-inch of insertion, in order to engage the electrical connection.

Figure 10. Installing a Drive Module

3. Tighten the top and bottom thumbscrews, securing the drive module into the library.
4. Remove the new connector plate from the replacement drive.
5. Install the original ribbon connector and plate inside the replacement drive module (see Figure 8 "Ribbon Cable and Connector").
6. Gently fold the ribbon cable (attached to the plate and SCSI cable), into the back of the drive module.
7. Holding the connector plate in place, tighten the thumbscrews on each side of the connector.

Bringing the Drive Online

Bring the new drive module online using the front panel display by following these steps.

1. Enter the Service or Administration menu.
2. Then enter the Online Drive Repair menu.
3. Select the drive module that has been replaced or installed, and press [OK].
4. Select [Put Drive Online].
5. If you have increased the number of drives since the last power cycle, or if you downloaded new drive firmware, you must power cycle the library.

The library will automatically run a self-test when the drive has been brought online. When the drive is successfully brought online, the new drive will adopt the SCSI ID of the current drive position.

SERVICE NOTE: The library will also confirm the new drive is online in the Service/Online Drive Repair menu.

NOTE: If the new drive has a different firmware revision than the drives that are already in the library, the library could go into a partial availability state due to a firmware mismatch. When this occurs, the front panel will partly display Partly Available, and the LED bar beneath the front panel display will be solid amber. This is not an indication of a failure, but may be an indication to download new drive firmware until all drives have the same firmware revision.

NOTE: You may need to use the host backup software to recognize the new drive when bringing it online. If the software does not have the capability to automatically detect the new drive, you may need to reboot the host.

For Service Personnel

Removing and Replacing the Transport Assembly

Level of Difficulty: [4] Difficult

The instructions for this assembly are divided into the following sections:

• Accessing the Transport Assembly
• Removing the Transport Assembly
• Replacing the Transport Assembly
• Replacing the Cover

Accessing the Transport Assembly

Use the following steps to access the transport assembly:

WARNING: Failure to extend the anti-tip foot of the rack could result in damage to the library and/or personal injury.

1. Power off the library.
2. If the library is rackmounted, use the following steps to slide it forward in the rack:
   1. Lower the rack's leveler feet, and fully extend the anti-tip foot at the bottom front of the rack.
   2. Pull out the front doors and loosen the thumbscrews that secure the library to the rack.
   3. Push the library out until it hits the latch stops.
3. Remove the eight #4-40 x .25 (82-degree flathead with Torx T-8 head) screws to remove the top cover. You may have to slide the cover forward to remove it from the rack.

Figure 11. Access to the Transport Assembly

Removing the Transport Assembly

Use the following steps to remove the transport assembly:

1. Using the finger-holes in the top of the transport assembly, lift the assembly up and out of the library (see Figure 12 "Removing the Transport Assembly").

CAUTION: Use care to protect the flat, umbilical cable attached to the bottom of the transport assembly when lifting.

Figure 12. Removing the Transport Assembly

2. Place the transport assembly on top of the library, and disconnect the umbilical cable by pulling the tabs outward (see Figure 12 "Removing the Transport Assembly").

Replacing the Transport Assembly

1. Connect the umbilical cable (see Figure 12 "Removing the Transport Assembly"). Ensure that it clicks into place.
2. Lower the transport assembly into the library, ensuring that the umbilical cable folds properly as you lower the assembly.

Replacing the Cover

1. Replace the top cover by inserting all screws and tighten.
2. If the library is rackmounted, replace the screws behind the front doors that secure the library in place.

For Service Personnel

Removing and Replacing the Motherboard

Level of Difficulty: [4] Moderate to Difficult

Removing the motherboard requires a series of disassembly steps to access the board. Review the entire removal process before beginning this procedure.

Removing the Motherboard

CAUTION: This library contains very sensitive electronic components. It is important to follow the proper procedures for preventing electrostatic discharge (ESD). Use wrist-grounding straps and antistatic mats when removing and replacing the major assemblies. Failure to follow proper procedures could damage the circuitry.

Use the following steps to remove the motherboard:

1. Power off the library.
2. Record the location of all cables and cords in order to replace at the end of this procedure.
3. Disconnect all external cables from the back of the library.
4. Remove the following:
   • Power supply
   • Drive modules
   • Cards
   • Vacant card slot and drive covers
5. Disconnect all cables on the back of the motherboard (see Figure 13 "Motherboard Cable Connections").

Figure 13. Motherboard Cable Connections

1	Display cable connector
2	Fan cable
3	Umbilical cable
4	Door lock power cable
5	Guide pins

6. Remove ten #4-40 x .625 T-10 screws from the motherboard (see Figure 14 "Screw Locations on the Motherboard"). Use a 8 inch x 1/4 inch magnetic extension to remove these screws.

Figure 14. Screw Locations on the Motherboard

1	Four #4 - 40 x .625 T-10 screws in the card bay area
2	Three #4 - 40 x .625 T-10 screws in the drive bay area
3	Three #4 - 40 x .625 T-10 screws in the power supply bay

7. Loosen the thumbscrews on the sheet-metal cover nearest the left drive bay and rotate the cover clockwise (see Figure 15 "Rotating the Sheet-Metal Cover").

Figure 15. Rotating the Sheet-Metal Cover

WARNING: Failure to extend the anti-tip foot of the rack could result in damage to the library and/or personal injury.

8. If the library is rackmounted, use the following steps to slide it forward in the rack.
   1. Lower the leveler feet, and fully extend the anti-tip foot at the front of the rack.
      
   2. Pull out the front doors and unscrew the thumbscrews that secure the library to the rack.
   3. Push the library out until it hits the stop bracket (approximately 2/3 out of the rack). If the library is rackmounted, remove the right side panel of the rack to access the motherboard.
9. Remove the Torx #4-40 x .312 screws from the library's right-side panel, shown in Figure 16 "Removing Two Side Panels" (right, viewed from the front of the library), and slide the panels off the library.

Figure 16. Removing Two Side Panels

10. Open the front door on the right side for more room. Disconnect the magazine harness cable from the front of the motherboard by pushing the ejection tabs on the connector outward (see Figure 17 "Magazine Lock Harness Cable Connection").

Figure 17. Magazine Lock Harness Cable Connection

11. Carefully remove the motherboard from the side of the library (see Figure 18 "Removing the Motherboard").

Figure 18. Removing the Motherboard

Replacing the Motherboard

1. Insert the new motherboard into the side of the library. Align it by using the guide pins near the drive bays (see Figure 13 "Motherboard Cable Connections").
2. Replace the ten screws that secure the motherboard to the library chassis (see Figure 14 "Screw Locations on the Motherboard").
3. Connect all cables to the motherboard (see Figure 13 "Motherboard Cable Connections" and Figure 17 "Magazine Lock Harness Cable Connections").
4. Replace the library's side panels, and tighten the screws (see Figure 16 "Removing Two Side Panels").
5. Push the library fully into the rack (if needed), and secure it to the rack.
6. Rotate the sheet-metal cover back into place, and tighten the thumbscrew.
7. Replace the library cards, drive, vacant slot covers, and power supply.
8. Replace all external cables and cords.
9. Connect the power cord into a grounded power outlet and power on the library.

For Service Personnel

Removing and Replacing the Power Supply

Level of difficulty [1] Easy

A failing power supply disables the library.

Removing the Power Supply

1. Power off the library.
2. Disconnect the power cord from the back of the power supply.
3. Loosen the thumbscrews at the top and bottom of the power supply.
4. Remove the stop bracket.

Figure 19. Removing the Stop Bracket

5. Remove the power supply with one hand and pull outward. Support the bottom of the power supply to avoid dropping the module.
   

Replacing the Power Supply

1. Grasp the power supply handle with one hand while supporting the bottom with your other hand. Align the power supply with the guide notch at the top of the power supply bay.
2. Fully insert the power supply into the library.
3. Replace the stop bracket.
4. Tighten the two thumbscrews.
5. Connect the power cord to the power supply.

For Service Personnel

Removing and Replacing the Front Panel Display

Level of Difficulty: [3] Medium

Removing the Front Panel Display

CAUTION: This library contains very sensitive electronic components. It is important to follow the proper procedures for preventing electrostatic discharge (ESD). Use wrist-grounding straps and antistatic mats when removing and replacing the major assemblies. Failure to follow proper procedures could damage the circuitry.

1. Power off the library.
2. Remove the display cover and chin plate underneath the display on the existing library module. The screw locations are indicated in Figure 20 "Removing the Chin Plate and Front Cover."
3. Remove the display cover by lifting it upward and away from the library.

Figure 20. Removing the Chin Plate and Front Cover

4. Remove the two 6-32 screws that connect the display to the chassis (see Figure 21 "Removing the Front Panel Display").

Figure 21. Removing the Front Panel Display

5. Remove the front panel display by sliding it upward, then gently lifting it away from the front of the library.
6. Disconnect the cable from the back of the display by grasping the sides of the connector and pulling outward (see Figure 22 "Connecting the Front Panel"). Place the front panel in an ESD-protected area.

Replacing the Front Panel Display

1. Connect the display cable to the front panel connector. The display attaches to two tabs on the side of the display opening. Attach the display on the tabs and slide it down.
2. Install the two long 6-32 T-10 screws that are next to the software keys to secure the display to the chassis (see Figure 22 "Connecting the Front Panel").

Figure 22. Connecting the Front Panel

3. Reinstall the display cover by sliding it downward (see Figure 20 "Removing the Chin Plate and Front Cover"). Tighten the two Phillips head 6-32 screws to secure the display cover in place.
4. Install the viewing window, and tighten the two Phillips head screws to secure the window in place.
5. Install the four screws that connect the chin plate.

For Service Personnel

Removing and Replacing a Cosmetic Door

Removing a Cosmetic Door Face

Level of difficulty: [2] Easy to Medium

CAUTION: To avoid breaking the tab, do no use excessive force.

1. Pull the front door outward. Use the front panel display or key, if necessary, to unlock the door.
2. Remove the front magazine by lifting the handle on the top of the magazine and pulling upward.
3. Twist the release tab on the back of the cosmetic door and simultaneously pull upward on the sheet-metal tab to release (see Figure 23 "Removing the Front Door Face").

Figure 23. Removing the Front Door Face

1	Release tab
2	Sheet-metal tab
3	Cosmetic door connecting hooks

Replacing a Cosmetic Door

1. Insert the cosmetic door's connecting hooks through the holes in the front of the door.
2. Holding the cosmetic door in place, align the holes in the sheet-metal with the holes in the door front.
3. Push the sheet-metal tab downward so that the sheet-metal plate clicks into place beneath the plastic tab.
4. Replace the magazine, and close the door.

Upgrading Firmware

This section details the processes for upgrading library and drive firmware. Some of the processes used for upgrading library firmware are different from those used to upgrade drive firmware.

Firmware can be downloaded by:

• Using the remote management card (library only)
• Using a firmware upgrade tape (drive only)
• Using a Customer Engineer (CE) diagnostic tool (drive and library)

NOTE: After upgrading firmware, library configuration settings will revert back to the factory defaults, which could affect remote management. For a complete list of settings, see "Configuring the Library."

Checking the Firmware Revision

Before downloading new firmware, check your current firmware revisions.

NOTE: If the library is in a partial availability state due to a firmware mismatch, new firmware must be downloaded to resolve the condition. See "Partial Availability State."

Check your current firmware revisions by following these steps:

1. Ensure the library is powered on.
2. Use the following menu from the front panel:
   
   Main Menu - > Information - > Firmware Revisions
   
   
3. From the Firmware Revisions menu, use [More] to view the drive firmware revisions.

You can also check your current firmware revisions via the remote management card:

1. Enter the designated IP address into the Web browser to launch the Web-Based Library Administrator pages. (See "Configuring the Remote Management Card.")
2. Select the [Report] tab.
3. Scroll down to the Firmware Revisions section of the page to view your library and drive firmware revisions.

NOTE: Ensure that your backup software does not "SCSI reserve" the library, as this can prevent a firmware download.

Using the Remote Management Card (library firmware only)

NOTE: These firmware files must be loaded onto the local host computer before downloading firmware.

NOTE: The library administrator password is required for this process and is not set by default. If the password is not set, you will not be permitted to download firmware. (See "Enabling and Changing the Password".)

All library components, except drives, can be easily downloaded from the remote management card (see "Using the Remote Management Card.")

1. Once the library is configured for network access, enter the IP address within your web browser to launch the Web-Based Library Administrator pages.
2. Select the [Configuration] tab from the main screen.
3. Select the [Firmware Download] button.
4. Enter the full path name for the download file, or use the Browse button to locate the file.
5. Select the [Start Firmware Download] button to begin the actual process of downloading the library firmware.

Once the download process begins, the progress and status of the download will display on the lower half of your screen. The firmware download may take several minutes to complete.

Using a Firmware Upgrade Tape (drive firmware only)

1. Contact your Dell service representative to get the drive upgrade tape.
2. Ensure the drive is empty. The drive icon(s) on the Home screen indicates the presence of a tape in the drive. If a tape is in the drive, use the front panel display to return the tape to a storage slot.
3. Place the firmware upgrade tape in an available storage slot in the library, and note the slot number.
4. Use the following menu to perform the firmware upgrade:
   
   Main Menu -> Administration -> Upgrade Drive Firmware
   
   
5. From the Upgrade Drive Firmware menu, use the [-] or [+] key to select the slot containing the firmware upgrade tape. Select [OK].
6. Use the [-] or [+] key to select the drive that you want to upgrade. Select [OK].
7. Watch the upgrade status on the library's front panel. Only drives that are online and empty (not reserved) can be upgraded.
8. Remove the firmware upgrade tape from the library.

NOTE: When the operation is complete, the tape will be returned to its original slot.

For Service Personnel

Using a CE Diagnostic Tool

You can use library diagnostic tools or third-party service tools to update library and drive firmware from a laptop computer.

When using a narrow single-ended SCSI host adapter in the laptop, additional equipment will typically be needed:

• A 50-pin to 68-pin adapter cable (ideally with high-byte termination). If using the standard Adaptec PCMCIA to HD 50-pin male cable, the adapter cable will need a HD 50-pin female end.
• A single-ended SCSI terminator (if the library/drive is LVDS).

NOTE: An LVDS terminator cannot be used when connecting to a single-ended Adaptec PCMCIA card because the dif sense line is not used on PCMCIA SCSI cards.

The general procedure for using a CE diagnostic tool is as follows:

1. If necessary, install the diagnostic tool and firmware files onto the laptop.
2. Ensure that the library is not being accessed by the host system.
3. Ensure that the library is powered off.
4. Disconnect the device from the host system, noting the cabling and termination.
5. Connect the laptop SCSI interface to the device, using the appropriate equipment and appropriate termination at the device end.
6. Power on the library. Wait for the library to complete the power-on test and inventory check, and power on the laptop.
7. This step if for upgrading drive firmware only. If upgrading library firmware, continue to step 8.
   Ensure that the drive is online (green LED is on, and yellow LED is off). If not, place it online through the front panel.
   1. Enter the Service then the Online Drive Repair menus.
   2. Select the drive and [Put Drive Online].
      The library will automatically run a self-test when the drive has been brought online. Wait until the self-test completes, and then scan the SCSI bus or restart the diagnostics program.
8. Download the firmware to the devices using the diagnostic tool.
9. Power off the library.

NOTE: On diagnostic programs that do not flip the drive handle automatically, you must power cycle the library for the drive firmware download to be completed.

10. Disconnect the laptop and reconnect the library to the host system. Be sure to match the original cabling and termination setup.
11. Power on the library and verify the device can be accessed from the host.
    

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