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PART NUMBER

EDITION NUMBER

99607

44xx/93xx/L55xx
MAINTENANCE MANUAL
PRODUCT TYPE

HARDWARE

Automated Cartridge System

44xx/93xx/ L55xx Automated Cartridge System


Maintenance Manual

Information contained in this publication is subject to change without notice. Comments concerning the contents of this publication should be directed to:

Global Learning Solutions Storage Technology Corporation One StorageTek Drive Louisville, CO 80028-3256 USA
http://gandalf.stortek.com/gls/document_comments.shtml

Information Control The information in this document, including any associated software program, may not be reproduced, disclosed or distributed in any manner without the written consent of Storage Technology Corporation. Should this publication be found, please return it to StorageTek, One StorageTek Drive, Louisville, CO 80028-5214, USA. Postage is guaranteed.

Export Destination Control Statement These commodities, technology or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. law is prohibited.

StorageTek, the StorageTek logo, are trademarks or registered trademarks of Storage Technology Corporation. Other products and names mentioned herein are for identification purposes only and may be trademarks of their respective companies.

1993, 2003 Storage Technology Corporation. All rights reserved.

ii

Sixth Edition

99607

List of Pages
Document Title: Manual Part Number: Initial Release Date: Seventh Edition Date: Nearline Automated Cartridge System Maintenance Manual for Models 44xx/93xx/L55xx 99607 March 1988, EC 17520 July 2003, EC 111855

Total number of pages in this document is 842, consisting of the following: Pages Cover Blank Page Title Page Copyright Page iii through liv 1-1 through 1-34 2-1 through 2-34 3-1 through 3-46 4-1 through 4-60 5-1 through 5-46 6-1 through 6-430 7-1 through 7-4 A-1 through A-86 B-1 through B-8 Glossary-1 through Glossary-8 Index-1 through Index-30 Readers Comment Form Business Reply Mailer Blank Page Back Cover Disposition

99607

Seventh Edition

iii

Summary of Changes
EC 17520 53488 111528 111750 111855 Date March 1988 Edition Initial release Refer to this edition for a description of the changes. Refer to this edition for a description of the changes. Refer to this edition for a description of the changes. Included Z Belt and Z Belt Guide maintenance procedures. Description

October 1988 Fourth August 2000 April 2002 July 2003 Fifth Sixth Seventh

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Contents
List of Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxiii Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxv
Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxv Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxxvi Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxvii Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxxviii Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxxix StorageTeks External Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxxix Customer Resource Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxxix e-Partners Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxxix Global Services Support Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xl Documents on CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xl

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xli
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xli Lifting Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xlii Shoulder, Elbow, Wrist, and Hand Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xlii Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xliii LSM Entry Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xliv Emergency Entry (Standard Access Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xlvi Emergency Entry (Optional Access Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xlvii Access Door Restoral (Following Entry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .l LSM Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . li Electrostatic Discharge (ESD) Damage Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lii ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lii ESD-Protection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liii Prepare the Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liii Access the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liii Replace Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liv Clean Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . liv

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1: General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1


General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Host Software Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 UNIX-Based Storage Server (4430 Attach) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Library Storage Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Cartridge Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 ACS Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Configuration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 ACS Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Minimal LSM Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Dual LSM Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Three LSM Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Orthogonal LSM Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Maximum (Dense Pack) Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 ExtendedStore LSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Cartridge Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

2: Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1


Displays, Controls, and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Library Management Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 4430 LMU Operators Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 4430 LMU Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 4430 LMU I/O Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Library Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 LCU Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 LCU Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 LCU CSE Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 LCU I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 LCU/LSM Signal I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 LCU/LSM Power I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Library Storage Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 LSM Standard Access Door and CAP Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 LSM Optional Access Door, CAPs and PCAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 LSM Operator Warning Panel (inside LSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 LSM Entrance Door EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 4480 Cartridge Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 4480 Cartridge Drive Control and Display Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

3: Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1


Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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Tools, Lubricants, and Parts Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Semi-Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 REI Card Cage Fans (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 EPO Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 21-Cell Cartridge Access Port Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Theta Harmonic Drive Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Theta Arm/Theta Arm Stop Assembly (Gear-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Theta Arm/Theta Arm Stop Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Z Channel Assembly (Leadscrew-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Z Channel Assembly (Belt-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Z Belt and Z Flex Guide (9310/L5510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Turntable Assembly (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Hand Assembly (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 4420 PTP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Long Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Modify LSM Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 System Level Checks Using HSC Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Theta Counter Shear Pin (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Bulbs (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Power-On Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 3270 Wrap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 IPM/Terminal Control Unit Status Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Terminal Control Unit-Based Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Channel Status Tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 LCU-CD Interface Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 LSMCD/Transport Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Interconnecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 CD Transport Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Functional Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Troubleshooting the LSM-CD/Transport Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 IPL Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

4: Power System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1


LMU Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 LMU Front Panel Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 LMU Internal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Circuit Operation Description (LMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 LMU Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Control CardLL Card (LMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 12 V Power Supply Assembly (MR Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 +5 V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 LCU Power Supply (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Standard AC Distribution Box (LCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 AC Control (LK) Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 LCU Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 LCU Standard Bulk DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 LCU AC Dual Power Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Similarities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Dual Power OptionFunctional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Dual Power OptionInternal Logic Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Dual Power OptionAC Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 LCU DC Power Supply (Dual Power Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Power Regulator (DX/MV) Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Overvoltage and Undervoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Input Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Interface and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Power Regulator Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 LSM Power Supply (4410 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Output Power (4410 LS Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Overvoltage and Undervoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Input Voltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Thermal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Regulator (LS) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Margining Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 LSM Interlock Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 LSM Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 LSM Emergency Power-Off (EPO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

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Power Supply Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LMU and 9310/L5510 Standard Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9310/L5510 Dual Line Cord Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4480 Cartridge Drive Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-58 4-58 4-58 4-59

5: General Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1


Fault Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LMU Power Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LCU/LSM Power Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

6: Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1


LMU Components (4430) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Maintenance on a Non-Functioning SLMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Normal Maintenance/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Unusual Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Maintenance on A Live SLMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Maintenance on A MLMU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Printed Circuit (LA, LB, LC/NN, and LI) Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Motherboard Assembly (LJ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 AC Box (Power Supply Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Older Model DC Power Supply (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Newer Model DC Power Supply (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 12 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Operator Panel (LD Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 IPL/Reset (MF Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor (BY Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCU Components4411/9311/L5511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCU Printed Circuit Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motherboard Assembly (LT Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Box Assembly (LQ/PLQ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Assembly (LR Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Power Supply Assembly (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Power Supply Assembly (Dual Power Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulk Regulator (DC Power Supply) AssemblyStandard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power Supply AssemblyDual Power Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transformer (Single AC Source Power Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor (BY Card, Card Cage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCU Card Cage Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-24 6-24 6-26 6-26 6-26 6-31 6-31 6-31 6-32 6-32 6-32 6-32 6-35 6-35 6-37 6-38 6-38 6-38 6-40 6-40 6-40 6-42 6-42 6-43 6-46 6-46 6-48 6-49 6-49 6-49 6-51 6-51 6-51 6-53 6-53 6-55 6-56 6-56 6-56 6-57 6-57 6-57

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LQ/PLQ and DX/MV Card Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IPL RESET (NB Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Regulator Assembly (DX or MV Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LSM Components4410/9310/L5510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REI Printed Circuit Cards (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REI Motherboard (4410 LM Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor (4410 BY Card, REI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REI Card Cage Fan Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLS/PLF Module (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLR Card (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLS/PLF Fan Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PMC Card (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Stop Card (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Stop CardMC1 Card (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Stop Assembly (4410 Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-59 6-59 6-59 6-61 6-61 6-61 6-63 6-63 6-63 6-65 6-65 6-65 6-67 6-68 6-68 6-70 6-71 6-71 6-71 6-72 6-72 6-72 6-74 6-74 6-74 6-76 6-76 6-76 6-78 6-78 6-78 6-80 6-80 6-80 6-82 6-82 6-84 6-85 6-85 6-87 6-88 6-88

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Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90 Theta Stop Assembly (4410 New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93 Theta Stop Shear Pin (4410 New Style Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94 Theta Home Opt Sensor and Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 LSM Interlock Card (MG Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98 Pinning Procedure4410 Z Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101 Turntable Interface Card (4410 MB Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103 Gripper Assembly (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 Gripper Assembly (9310 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 Cartridge Fingers (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111 Roll Interface Card (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112 Z Sensor Card (4410 ME Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118 Z Sensor Flag (4410 Belt-Driven Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119 Reach Sensor MK Card (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121 Theta Flex Coil Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126 Theta Arm Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127

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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Flex Circuit Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Motor Encoder Cable (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Motor Power Cable (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Counter Shear Pin (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Turns Counter Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Motor Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Encoder Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Arm Assembly (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theta Drive Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Flex Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Motor/Encoder Assembly (4410 Leadscrew-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Motor/Encoder Assembly (4410 Belt-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camera Assembly with Mounting Plate (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Assembly without Camera (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-127 6-128 6-133 6-133 6-133 6-138 6-138 6-138 6-138 6-138 6-139 6-139 6-139 6-139 6-142 6-142 6-142 6-144 6-144 6-144 6-147 6-147 6-148 6-150 6-150 6-151 6-155 6-155 6-157 6-160 6-160 6-162 6-163 6-163 6-165 6-166 6-166 6-168 6-169 6-169 6-169 6-170

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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Front Plate Bearing Kit (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Assembly (9310/L5510 Only, Din Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable/Z Transport Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Transport Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Transport Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Flex Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camera W/Bracket (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLE Card (9310/L5510 LED Lamps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Motor/Encoder (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turntable Bearing Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Column Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Motor Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Motor Flex (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Transport Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Belt (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-170 6-172 6-173 6-173 6-173 6-175 6-176 6-176 6-178 6-181 6-181 6-182 6-187 6-187 6-187 6-188 6-188 6-188 6-190 6-190 6-190 6-190 6-190 6-192 6-192 6-192 6-194 6-195 6-195 6-198 6-199 6-199 6-199 6-201 6-201 6-201 6-202 6-202 6-206 6-207 6-207 6-209

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Z Channel-to-Z Channel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Channel Re-tightening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Flex Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Channel Assembly (4410 Leadscrew-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Channel Assembly (4410 Belt-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Sensor and Tach Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Leadscrew/Mount Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterweight Plate Bearings (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Plate Bearings (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Leadscrew Top/Bottom Bearings (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterweight Pulley Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterweight Cable (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Belt-Drive Pulley Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Drive Belt (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Drive Belt Slide (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Roller Assembly (4410 Belt-Driven Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-209 6-210 6-214 6-214 6-215 6-218 6-218 6-222 6-223 6-223 6-228 6-230 6-230 6-230 6-233 6-233 6-237 6-239 6-239 6-241 6-242 6-242 6-244 6-245 6-245 6-246 6-250 6-250 6-250 6-252 6-252 6-252 6-254 6-254 6-256 6-257 6-257 6-257 6-259 6-259 6-259 6-260

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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z Roller Plate (4410 Belt-Driven Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Roll Sensor Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll Flat Flex Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll Flex Coaxial Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical Sensor Cable Assembly4410 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LSM Hand and Interior Ceiling Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camera and Gusset Lamps Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camera and Gusset Lamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roof Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roof Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Light Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermal Switch AssemblyInner Roof Gusset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor (BY Card, Lower Gusset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor (BY Card, LCU Wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ND CardStandard Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAD Switch and Cable Assembly (Standard Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-260 6-260 6-262 6-262 6-262 6-263 6-263 6-263 6-265 6-265 6-265 6-267 6-267 6-267 6-270 6-270 6-272 6-273 6-273 6-273 6-275 6-275 6-275 6-275 6-275 6-276 6-276 6-276 6-276 6-276 6-276 6-277 6-277 6-278 6-278 6-278 6-278 6-279 6-279 6-279 6-280 6-280

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99607

Contents

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ND CardOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MW CardOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MZ CardOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display PanelOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAD Switch and Cable Assembly (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAD Switch (LAD Switch Assembly, Header) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Latch Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Latch (Compression) Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interlock SwitchHeader Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Interlock Switch SubassemblyHinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EPO Contact Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Door Springs (21-Cell CAP Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Locked Solenoid Cable Assembly (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Solenoid Lock Assembly (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-282 6-282 6-282 6-282 6-283 6-283 6-283 6-285 6-285 6-285 6-286 6-286 6-286 6-287 6-287 6-287 6-289 6-289 6-289 6-291 6-291 6-291 6-293 6-293 6-293 6-295 6-295 6-297 6-298 6-298 6-300 6-301 6-301 6-303 6-303 6-303 6-305 6-306 6-306 6-306 6-308 6-308

99607

Seventh Edition

xvii

Contents

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Door Latch Sensor (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Latch Sensor Bracket Assembly (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Door Locked Switch (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NA CardOperator Panel (21- Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access Door Cable Assembly (Standard Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access Door/MZ Card, ME8 Harness (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hinge, CAP 1/0-MW 0/1 Harness (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power, MZ Card Cable Assembly (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MW to CAP Cable Assembly (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Open/Close Sensor (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magazine Sensor Assembly (Optional Door CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCAP Open/Close Sensor AssemblyOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam Followers21-Cell CAP Safety Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Spring21-Cell CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-308 6-311 6-311 6-311 6-313 6-313 6-313 6-314 6-314 6-315 6-316 6-316 6-316 6-318 6-318 6-318 6-320 6-320 6-323 6-323 6-323 6-324 6-325 6-325 6-325 6-326 6-326 6-326 6-327 6-327 6-327 6-329 6-329 6-331 6-331 6-331 6-332 6-334 6-334 6-334 6-334 6-334

xviii

Seventh Edition

99607

Contents

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas SpringOptional Door CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCAP TrayOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCAP HarnessOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HBO Sensor/Switch AssemblyDoor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP LatchStandard Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Door Latch AssemblyOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RH Mod Slam LatchOptional Door CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAP Latch Solenoid AssemblyOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCAP Latch AssemblyOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LH Mod Slam LatchOptional Door PCAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCAP Latch Solenoid AssemblyOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ionization Smoke DetectorRoof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Photo-electric Smoke DetectorRoof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smoke Detector Base AssemblyRoof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-334 6-336 6-336 6-336 6-338 6-338 6-340 6-340 6-340 6-341 6-342 6-342 6-342 6-345 6-345 6-345 6-347 6-347 6-349 6-350 6-350 6-350 6-351 6-351 6-351 6-352 6-352 6-354 6-354 6-354 6-355 6-355 6-355 6-356 6-357 6-357 6-357 6-357 6-357 6-357 6-358 6-358

99607

Seventh Edition

xix

Contents

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Motor/Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 Master PTP Cam-Optical Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 Slave PTP Cam-Optical Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Leadscrew Flange Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Array Flange Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Extension Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTPNC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTPBall Bushing/Shaft Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4420/L5520 PTP Rotation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9320 CEM Master Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9320 CEM Slave Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9320 CEM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-358 6-358 6-358 6-361 6-361 6-361 6-362 6-362 6-362 6-363 6-364 6-364 6-364 6-365 6-365 6-366 6-368 6-368 6-368 6-369 6-369 6-370 6-370 6-370 6-370 6-371 6-371 6-372 6-373 6-373 6-374 6-376 6-376 6-376 6-379 6-379 6-381 6-387 6-387 6-389 6-394 6-394

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Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PNC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DDM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Switch Panel (DO Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WindowWall (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-401 6-420 6-422 6-422 6-422 6-423 6-423 6-423 6-425 6-425 6-425 6-427 6-427 6-427 6-429 6-429 6-429

7: Equipment Restoral Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1


Library Management Unit Restoral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Library Control Unit Restoral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Library Storage Module Restoral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Long Initialization Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-2 7-4

A: Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1


System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Host Software Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Library Management Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 LMU Functional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Central Processor Module (LA Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Memory (LI Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Peripheral Interface Module (LB Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Interface Processor Module(s) (LC Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 RS-423 Interface Processor Module (NN CardUNIX Only) . . . . . . . . . . . . . . . . . . . . A-12 Operator Panel (LD Card), Service Panel (MF Card) . . . . . . . . . . . . . . . . . . . . . . . . . . A-15 Field Replaceable Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16 LMU Diagnostic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16 LMU Functional Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16 LMU Power-on and IPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17 Dual LMU Init Logic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17 LSM State Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18 Host Message Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20

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Cartridge Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Label Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Location Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Resource Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21 Motion Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22 Recovery of In-Transit Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23 Recovery of Failed Motion Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 CAP/Priority CAP Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 CAP Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 CAP Reservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 CAP Enter and Eject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 CAP Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 Paired CAP Mode (80-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 Cataloging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-29 Catalog Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Unsolicited Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Status and Performance Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31 HSC Recovery Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-33 Library Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34 LCU Functional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-34 Central Processor Module (LZ/PLZ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-38 Pass-Thru Port Control (LP/LPP Cards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-39 Interrupt/Timer (LY Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-41 Camera/Solenoid (LW/PLW Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-43 REI/Theta Interface (LX/PLX Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-45 Theta Servo Card (LQ/PLQ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-47 Theta Servo (LQ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-47 Theta Servo (9311/L5511 PLQ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-49 Theta Sensor (9310/L5510 PMC) Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-52 Operator Panel (LR Card), Service Panel (NB Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-52 Field Replaceable Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-53 LCU Diagnostic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-53 LCU Functional Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-53 LSM Power-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-54 LSM Power-on, IPL and Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-54 Quick Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-55 LSM States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-55 Configuration and Status Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-56 Motion Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-56 CAP Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-57 PTP/CEM Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-58 Access Door Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-58

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Transport Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-59 Unsolicited Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-59 LSM Idle Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-60 LCU-LSM Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-61 Library Storage Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-61 Walls and Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-62 LSM Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-63 Cartridge Access Port (21-Cell) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-63 Cartridge Access Port (80-Cell)/PCAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-64 80-Cell CAP Interface Board (MZ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-64 80-Cell CAP Solenoid Driver Board (MW Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-64 80-cell CAP Sensors (ME Cards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-65 Pass-Thru Port/Cartridge Exchange Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-67 Theta Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-68 Turntable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-68 Hand Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-68 Finger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-69 Camera System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-69 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-69 Remote Electronics Interface (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-69 Turntable Servo (4410 LU Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-71 Reach and Finger Servo (4410 LN Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-74 Roll Servo/Camera Lamp (4410 LO Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-74 Z Servo (4410 LV Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-77 Remote Electronics Regulator (4410 LS Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-79 4480 Cartridge Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-82 Transport Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-82 LCU-Transport Interactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-83 Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-84 Manual Operation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-84 Manual Unload Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-84 Manual Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-85 Return to Library Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-85

B: 4430 LMU Terminal Control Unit Interface . . . . . . . . . . . . . . . . . . . . . . . . . B-1


Host Interface Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Approved Terminal Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Cable Type/Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 3299 Usage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Foreign Language Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 IBM 3274 1D, 21D, 31D, and 41D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 IBM 3174 1L, 11L, 21L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

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IBM 6020, 6120 (VM Server) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 IBM 9034 (ESCON Converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 McDATA MC74 41A, MC400 1L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7 Interface Diagnostic/Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index-1 Readers Comment Form

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Figure 1-1. Automated Cartridge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Figure 1-2. Typical ACS Logical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-3. UNIX-based Storage Server Block Diagram (4430 LMU Attach) . . . . . . . . . . . . . . . . . . . . . 1-5 Figure 1-4. 4430 Library Management Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Figure 1-5. 4430 LMU Motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Figure 1-6. 9311/4411 Library Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Figure 1-7. 9311/4411 LCU Motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Figure 1-8. Library Storage Module (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Figure 1-9. Library Storage Module (Sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Figure 1-10. Library Storage Module (Sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Figure 1-11. Library Storage Module4410 Robotics (Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Figure 1-12. Library Storage Module9310/L5510 Robotics (Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . 1-16 Figure 1-13. CAP Cartridge Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Figure 1-14. 4410 REI Motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Figure 1-15. 9310 PLR/PLS/PLF Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Figure 1-16. Minimal LSM Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Figure 1-17. Dual LSMs, Dual Hosts Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Figure 1-18. Triple LSMs, Linear Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Figure 1-19. Triple LSMs, Trefoil Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Figure 1-20. Orthogonal LSM Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Figure 1-21. Maximum (Dense Pack) LSMs Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Figure 2-1. 4430 LMU Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Figure 2-2. 4430 LMU Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Figure 2-3. 4430 LMU I/O Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Figure 2-4. 9311/L5511/4411 LCU Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Figure 2-5. LCU Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Figure 2-6. LCU CSE Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Figure 2-7. LCU I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Figure 2-8. LCU/LSM Signal I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Figure 2-9. LCU/LSM Power I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Figure 2-10. LSM Standard Door and CAP Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Figure 2-11. LSM Optional Access Door Latches/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Figure 2-12. LSM Operator Warning Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Figure 2-13. LSM Entrance Door EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Figure 2-14. Cartridge Drive Operator Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Figure 3-1. LSM Smoke Detector Pin-Out Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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Figure 3-2. Safety Door Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Figure 3-3. Theta Counter Shear Pin (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Figure 3-4. LMU Card Cage Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Figure 3-5. LCU Card Cage Indicators (4411/9311/L5511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Figure 3-6. REI Card Cage Indicators (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Figure 3-7. LQ Card Indicators and Test Points (4411) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Figure 3-8. LCU-to-CD/Transport Interface (Serial Numbers Below 879) . . . . . . . . . . . . . . . . . . . . . . 3-43 Figure 3-9. LCU-to-CD/Transport Interface (Serial Number 879 and Above) . . . . . . . . . . . . . . . . . . . 3-44 Figure 4-1. LMU AC Box Assembly and 12 VDC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . 4-3 Figure 4-2. Older Model LMU +5 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Figure 4-3. Newer Model LMU +5 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Figure 4-4. LMU Power Supply Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Figure 4-5. LCU AC Power Supply (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Figure 4-6. Standard LCU AC Box Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Figure 4-7. LCU Standard Bulk DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Figure 4-8. LCU Standard Bulk DC Power Supply Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Figure 4-9. Dual Power Option Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Figure 4-10. LCU Dual Power Option: AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Figure 4-11. LCU DC Power Supply (Dual Power Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Figure 4-12. DX Card Test Points/Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Figure 4-13. MV Card Test Points/Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Figure 4-14. LS Card Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Figure 4-15. LSM Interlock/EPO System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Figure 5-1. Fault Isolation Flow Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Figure 5-2. Fault Isolation Flow Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Figure 5-3. LMU Power Supply Troubleshooting Flowchart (Sheet 1 of 20) . . . . . . . . . . . . . . . . . . . . . . 5-6 Figure 5-4. LMU Power Supply Troubleshooting Flowchart (Sheet 2 of 20) . . . . . . . . . . . . . . . . . . . . . . 5-7 Figure 5-5. LMU Power Supply Troubleshooting Flowchart (Sheet 3 of 20) . . . . . . . . . . . . . . . . . . . . . . 5-8 Figure 5-6. LMU Power Supply Troubleshooting Flowchart (Sheet 4 of 20) . . . . . . . . . . . . . . . . . . . . . . 5-9 Figure 5-7. LMU Power Supply Troubleshooting Flowchart (Sheet 5 of 20) . . . . . . . . . . . . . . . . . . . . . 5-10 Figure 5-8. LMU Power Supply Troubleshooting Flowchart (Sheet 6 of 20) . . . . . . . . . . . . . . . . . . . . . 5-11 Figure 5-9. LMU Power Supply Troubleshooting Flowchart (Sheet 7 of 20) . . . . . . . . . . . . . . . . . . . . . 5-12 Figure 5-10. LMU Power Supply Troubleshooting Flowchart (Sheet 8 of 20) . . . . . . . . . . . . . . . . . . . . 5-13 Figure 5-11. LMU Power Supply Troubleshooting Flowchart (Sheet 9 of 20) . . . . . . . . . . . . . . . . . . . . 5-14 Figure 5-12. LMU Power Supply Troubleshooting Flowchart (Sheet 10 of 20) . . . . . . . . . . . . . . . . . . . 5-15 Figure 5-13. LMU Power Supply Troubleshooting Flowchart (Sheet 11 of 20) . . . . . . . . . . . . . . . . . . . 5-16 Figure 5-14. LMU Power Supply Troubleshooting Flowchart (Sheet 12 of 20) . . . . . . . . . . . . . . . . . . . 5-17 Figure 5-15. LMU Power Supply Troubleshooting Flowchart (Sheet 13 of 20) . . . . . . . . . . . . . . . . . . . 5-18 Figure 5-16. LMU Power Supply Troubleshooting Flowchart (Sheet 14 of 20) . . . . . . . . . . . . . . . . . . . 5-19 Figure 5-17. LMU Power Supply Troubleshooting Flowchart (Sheet 15 of 20) . . . . . . . . . . . . . . . . . . . 5-20 Figure 5-18. LMU Power Supply Troubleshooting Flowchart (Sheet 16 of 20) . . . . . . . . . . . . . . . . . . . 5-21 Figure 5-19. LMU Power Supply Troubleshooting Flowchart (Sheet 17 of 20) . . . . . . . . . . . . . . . . . . . 5-22

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Figure 5-20. LMU Power Supply Troubleshooting Flowchart (Sheet 18 of 20) . . . . . . . . . . . . . . . . . . . 5-23 Figure 5-21. LMU Power Supply Troubleshooting Flowchart (Sheet 19 of 20) . . . . . . . . . . . . . . . . . . . 5-24 Figure 5-22. LMU Power Supply Troubleshooting Flowchart (Sheet 20 of 20) . . . . . . . . . . . . . . . . . . . 5-25 Figure 5-23. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 1 of 18) . . . . . . . . . . . 5-27 Figure 5-24. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 2 of 18) . . . . . . . . . . . 5-28 Figure 5-25. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 3 of 18) . . . . . . . . . . . 5-29 Figure 5-26. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 4 of 18) . . . . . . . . . . . 5-30 Figure 5-27. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 5 of 18) . . . . . . . . . . . 5-31 Figure 5-28. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 6 of 18) . . . . . . . . . . . 5-32 Figure 5-29. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 7 of 18) . . . . . . . . . . . 5-33 Figure 5-30. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 8 of 18) . . . . . . . . . . . 5-34 Figure 5-31. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 9 of 18) . . . . . . . . . . . 5-35 Figure 5-32. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 10 of 18) . . . . . . . . . . 5-36 Figure 5-33. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 11 of 18) . . . . . . . . . . 5-37 Figure 5-34. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 12 of 18) . . . . . . . . . . 5-38 Figure 5-35. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 13 of 18) . . . . . . . . . . 5-39 Figure 5-36. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 14 of 18) . . . . . . . . . . 5-40 Figure 5-37. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 15 of 18) . . . . . . . . . . 5-41 Figure 5-38. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 16 of 18) . . . . . . . . . . 5-42 Figure 5-39. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 17 of 18) . . . . . . . . . . 5-43 Figure 5-40. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 18 of 18) . . . . . . . . . . 5-44 Figure 6-1. Printed Circuit Card Locations (LMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Figure 6-2. LMU Motherboard (LJ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Figure 6-3. LMU AC Power Cord Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Figure 6-4. 4430 LMU AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Figure 6-5. Older Model LMU DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Figure 6-6. Newer Model LMU DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Figure 6-7. 12 Volt Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Figure 6-8. LD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Figure 6-9. MF Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Figure 6-10. LMU Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Figure 6-11. LMU Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Figure 6-12. Mitsubishi Floppy Disk Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Figure 6-13. Panasonic Floppy Disk Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Figure 6-14. LCU Printed Circuit Card Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Figure 6-15. LCU Motherboard (LT Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Figure 6-16. Theta Box Assembly (LQ/PLQ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Figure 6-17. Operator Panel Assembly (LR Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Figure 6-18. Standard LCU AC Power Supply Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Figure 6-19. LCU AC Power Supply (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Figure 6-20. LCU AC Power Supply (Dual Power Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Figure 6-21. LCU Bulk Regulator (DC Power Supply AssemblyStandard) . . . . . . . . . . . . . . . . . . . . 6-50

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Figure 6-22. DC Power Supply AssemblyDual Power Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Figure 6-23. LCU Main Power Transformer (Standard AC Power Supply) . . . . . . . . . . . . . . . . . . . . . . 6-54 Figure 6-24. LCU Card Cage Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 Figure 6-25. LQ/PLQ and DX/MV Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 Figure 6-26. LCU NB Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 Figure 6-27. DX or MV Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64 Figure 6-28. REI Printed Circuit Cards (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 Figure 6-29. REI Motherboard (4410 LM Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Figure 6-30. REI Card Cage Fan Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Figure 6-31. PLS/PLF Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Figure 6-32. PLR Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Figure 6-33. PLS/PLF Fan Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Figure 6-34. PMC Card (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Figure 6-35. MC Card (4410 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Figure 6-36. MC1 Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 Figure 6-37. Theta Stop Assembly (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89 Figure 6-38. Theta Stop Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92 Figure 6-39. Theta Stop Shear Pin (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95 Figure 6-40. MG Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100 Figure 6-41. Pinning Locations of 4410 Z Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102 Figure 6-42. MB Card (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104 Figure 6-43. Gripper Assembly (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106 Figure 6-44. Gripper Assembly (9310) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108 Figure 6-45. Cartridge Fingers (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110 Figure 6-46. MD Card (4410 Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113 Figure 6-47. MD Card (4410 New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114 Figure 6-48. ME Card (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116 Figure 6-49. ME Card (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117 Figure 6-50. ME Card (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118 Figure 6-51. Z Sensor Flag (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120 Figure 6-52. MK Card (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122 Figure 6-53. Theta Flex Coil Harness (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124 Figure 6-54. Theta Flex Coil Harness (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-125 Figure 6-55. Theta Arm Assembly (9310/L5510 Only) (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . 6-130 Figure 6-56. Theta Arm Assembly (9310/L5510 Only) (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . 6-131 Figure 6-57. Theta Arm Assembly (9310/L5510 Only) (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . 6-132 Figure 6-58. Cables (9310/L5510 Only) (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135 Figure 6-59. Z Cables (9310/L5510 Only) (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136 Figure 6-60. Z Cables (9310/L5510 Only) (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-137 Figure 6-61. Theta Counter Shear Pin (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-141 Figure 6-62. Theta Counter Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143 Figure 6-63. Theta Motor Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-146

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Figure 6-64. Theta Encoder Assembly (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-65. Theta Arm Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-66. Theta Drive Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-67. Theta Drive Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-68. Z Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-69. Z Motor/Encoder Assembly (Leadscrew-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-70. Z Motor/Encoder Assembly (Belt-Driven) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-71. Camera Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-72. Hand Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-73. Turntable Assembly, 4410 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-74. Turntable Assembly, 4410 (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-75. Turntable Assembly (9310/L5510 Only, Din Connector) . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-76. L5510 Turntable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-77. 9310 Turntable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-78. Turntable/Z Transport Assembly Removal (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-79. Turntable/Z Transport Assembly Removal and Replacement (Sheet 2 of 4) . . . . . . . . . Figure 6-80. Turntable/Z Transport Assembly Removal and Replacement (Sheet 3 of 4) . . . . . . . . . Figure 6-81. Turntable/Z Transport Assembly Replacement (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . Figure 6-82. Camera and PLE (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-83. Turntable Motor/Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-84. Turntable Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-85. Z Column Assembly (9310/L5510 Only) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-86. Z Column Assembly (9310/L5510) (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-87. Z Motor and Flex (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-88. Z Transport Assembly (9310/L5510 Only) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-89. Z Transport Assembly (9310/L5510 Only) (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-90. Z Belt (9310/L5510 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-91. Z-to-Z Channel Check1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-92. Z-to-Z Channel Check2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-93. Z to Z Channel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-94. Transport Flex Assembly (9310/L5510 Only) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . Figure 6-95. Transport Flex Assembly (9310/L5510 Only) (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . Figure 6-96. Z Channel Assembly (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-97. Z Channel Assembly (Sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-98. Z Channel Assembly (Sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-99. Z Channel Assembly (Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-100. Z Channel Assembly (Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-101. ME Card (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-102. ME Card (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-103. ME Card (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-104. Z Leadscrew With Ballnut (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-105. Z Leadscrew With Ballnut (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-149 6-153 6-154 6-155 6-161 6-164 6-167 6-170 6-171 6-174 6-175 6-177 6-178 6-179 6-183 6-184 6-185 6-186 6-189 6-191 6-193 6-196 6-197 6-200 6-204 6-205 6-208 6-211 6-212 6-213 6-216 6-217 6-220 6-221 6-225 6-226 6-227 6-231 6-232 6-233 6-235 6-236

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Figures

Figure 6-106. Counterweight Plate Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-107. Z Arm Plate Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-108. Z Leadscrew Top/Bottom Bearings (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-109. Z Leadscrew Top/Bottom Bearings (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-110. Counterweight Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-111. Z Channel Assembly Counterweight Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-112. Z Belt Drive Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-113. Z Drive Belt And Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-114. Z Roller Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-115. Optical Roll Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-116. Roll Flat Flex Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-117. Roll Flex Coaxial Cable Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-118. Roll Flex Coaxial Cable Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-119. Z to Turntable Cable Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-120. Z to Turntable Cable Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-121. Turntable Optical Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-122. Thermal Switch AssemblyInner Roof Gusset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-123. Temperature Sensor (BY Card, LCU Wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-124. ND Card/LAD Door Switch and Cable Assembly (Standard Door) . . . . . . . . . . . . . . Figure 6-125. MW, MZ, and Display Card (Optional Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-126. ND Card/LAD Door Switch and Cable Assembly (Optional Door) . . . . . . . . . . . . . . Figure 6-127. LAD Switch Assembly, Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-128. Door Latch Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-129. Door Latch (Compression) Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-130. Header Assembly Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-131. Hinge Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-132. EPO Contact Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-133. Safety Door Spring (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-134. CAP Solenoid and Door Locked Switch (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-135. CAP Solenoid Lock Assembly (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-136. CAP Optical Sensor Cable Assembly (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-137. NA Card (21-Cell CAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-138. Standard Access Door Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-139. Optional Access Door Cables (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-140. Optional Access Door Cables (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-141. CAP Open/Close Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-142. Magazine SensorsCAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-143. PCAP Open/Closed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-144. Gas SpringCAP (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-145. Gas SpringCAP (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-146. PCAP Tray/HarnessOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-147. HBO Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-240 6-243 6-248 6-249 6-251 6-253 6-255 6-258 6-261 6-264 6-266 6-268 6-269 6-271 6-272 6-274 6-277 6-279 6-281 6-284 6-288 6-290 6-292 6-294 6-296 6-299 6-302 6-304 6-307 6-310 6-312 6-317 6-319 6-321 6-322 6-328 6-330 6-333 6-335 6-337 6-339 6-344

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Figure 6-148. CAP LatchStandard Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-149. CAP Latch SystemOptional Door (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-150. CAP Latch SystemOptional Door (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-151. PCAP Latch SystemOptional Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-152. 4420/L5520 Pass-thru Port FRU Components (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . Figure 6-153. 4420/L5520 Pass-thru Port FRU Components (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . Figure 6-154. 4420/L5520 PTP Rotation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-155. 9320 Master Solenoid Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-156. 9320 Master Tower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-157. 9320 Master Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-158. 4410 Wall Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-159. 9310 Wall Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-160. 9320 Tower Tool Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-161. 9320 Target Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-162. 9320 Slave Solenoid Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-163. 9320 Slave Tower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-164. 9320 Slave Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-165. 9320 Slave Receiver Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-166. 9320 Slave Receiver Target Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-167. 9320 Slave Solenoid Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-168. 9320 CEM Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-169. 9320 Cable Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-170. 9320 Master Tower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-171. 9320 Slave Tower Adjustment Screw and Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-172. 9320 Light Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-173. 9320 KEPS Nut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-174. 9320 CEM Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-175. 9320 Slave CEMPrimary Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-176. 9320 Master CEMLeveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-177. 9320 Slave CEMSecondary Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-178. 9320 Slave Light Shield Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-179. 9320 Cable Restraint and PNC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-180. 9320 Tower Tool Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-181. 9320 Master Receiver Ramp Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-182. 9320 Master Receiver Target Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-183. 9320 Slave Tower Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-184. 9320 Slave Receiver Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-185. 9320 Slave Receiver Target Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-186. 9320 Slave Solenoid Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-187. 9320 Slave Get Target Alignment (4410 LSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-188. 9320 Slave Get Target Alignment (9310 LSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-189. 9320 PNC Card Solenoid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-346 6-348 6-349 6-353 6-359 6-360 6-378 6-379 6-380 6-381 6-382 6-383 6-384 6-386 6-387 6-388 6-389 6-391 6-392 6-393 6-395 6-396 6-397 6-398 6-399 6-400 6-401 6-402 6-404 6-405 6-406 6-407 6-408 6-409 6-410 6-411 6-413 6-414 6-416 6-417 6-418 6-419

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Figures

Figure 6-190. 9320 PNC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-421 Figure 6-191. DDM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-424 Figure 6-192. DD Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-426 Figure 6-193. Operator Switch Panel (DO Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-428 Figure A-1. ACS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Figure A-2. LMU Block Diagram (IBM Hosts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Figure A-3. CPM (LA Card) Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Figure A-4. Memory (LI Card) Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Figure A-5. PIM (LB Card) Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Figure A-6. IPM (LC Card) Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11 Figure A-7. UNIX Storage Server Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Figure A-8. IPM (NN Card) Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15 Figure A-9. 4411/4410 LCU/LSM Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-35 Figure A-10. 9311/L5511/9310/L5510 LCU/LSM Block Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . A-36 Figure A-11. 9311/L5511/9310/L5510 LCU/LSM Block Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . A-37 Figure A-12. CPM Block Diagram (4410 LZ Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-39 Figure A-13. 4420/L5520 Pass-Thru Port Block Diagram (LP Card). . . . . . . . . . . . . . . . . . . . . . . . . . A-40 Figure A-14. Interrupt/Timer Block Diagram (LY Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-42 Figure A-15. Camera/Solenoid Block Diagram (LW Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-44 Figure A-16. REI/Theta Interface Block Diagram (LX Card). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-46 Figure A-17. Theta Servo Block Diagram (4411 LQ Card) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . A-48 Figure A-18. Theta Servo Connector Block Diagram (4411 LQ Card) (Sheet 2 of 2) . . . . . . . . . . . . . A-49 Figure A-19. Theta Servo Block Diagram (9311/L5511 PLQ Card). . . . . . . . . . . . . . . . . . . . . . . . . . . A-51 Figure A-20. 80-Cell CAP Access Door Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-65 Figure A-21. 80-Cell CAP Cabling/Connectors (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-66 Figure A-22. 80-Cell CAP Cabling/Connectors (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-67 Figure A-23. Remote Electronics Block Diagram (4410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-70 Figure A-24. Turntable Servo (LU Card) Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-72 Figure A-25. Remote Electronics Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-73 Figure A-26. Reach and Finger (LN Card) Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-75 Figure A-27. Roll Servo/Camera Lamp (LO Card) Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . A-76 Figure A-28. Z Servo Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-78 Figure A-29. RE Regulator (4410 LS Card)Power Circuits Block Diagram . . . . . . . . . . . . . . . . . . . A-80 Figure A-30. RE Regulator (4410 LS Card)Self-Check Block Diagram . . . . . . . . . . . . . . . . . . . . . . A-81

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Table 1-1. Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 Table 1-2. Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 Table 1-3. Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 Table 1-4. Operating Heat Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 Table 1-5. Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 Table 1-6. Service Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 Table 2-1. 4430 LMU Operator Panel Control and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Table 2-2. 4430 LMU Service Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Table 2-3. 4430 LMU I/O Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Table 2-4. LCU Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Table 2-5. LCU Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Table 2-6. LCU CSE Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Table 2-7. LCU I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Table 2-8. LCU/LSM Signal I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Table 2-9. LCU/LSM Power I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Table 2-10. LSM Standard Access Door Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Table 2-11. 4480 Cartridge Drive/Operator Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . 2-31 Table 3-1. Models Supported in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Table 3-2. Tools, Lubricants, and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Table 3-3. 4430 LMU Card Cage Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Table 3-4. LCU Card Cage Indicators and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Table 3-5. REI Card Cage Indicators and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Table 3-6. LQ Card Indicators and Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Table 3-7. LSM-to CD Transport Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Table 4-1. LMU AC Box Assembly and 12 VDC Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Table 4-2. Older Model LMU, +5 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Table 4-3. Newer Model LMU +5 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Table 4-4. LCU Single Power Cord: AC Supply Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Table 4-5. LCU AC Power Supply (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Table 4-6. LCU Standard Bulk DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Table 4-7. Dual Power OptionDifferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Table 4-8. Dual Power Option Logic Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Table 4-9. LCU AC Power Option AC Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Table 4-10. LCU DC Power Supply (Dual Power Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Table 4-11. Output Voltages for the DX and MV Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Table 4-12. DX Card Indicators/Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

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Table 4-13. MV Card Indicators/Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Table 4-14. LS Card Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Table 4-15. LS Card Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Table 4-16. LS Card Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Table 4-17. MG Card Truth Table (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 Table 4-18. MG Card Truth Table (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 Table 4-19. J-800 Interlock Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Table 4-20. J-801 LCU Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Table 4-21. J-802 Warning Signs Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Table 4-22. J-803 Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 Table 4-23. J-804 LSM EPO Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 Table 4-24. EPO Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Table 4-25. LSM Safety Interlock Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57 Table 5-1. LCU Power Supply (Dual Line Cord): Fault Isolation Table . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 Table 6-1. Turntable/Z Transport Assembly Parts Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-181 Table 6-2. Z Transport Assembly (9310/L5510 Only) Parts Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-202 Table 6-3. Turntable Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-210 Table 6-4. Transport Flex Assembly (9310/L5510 Only) Parts Guide . . . . . . . . . . . . . . . . . . . . . . . . . 6-214 Table B-1. Maximum Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

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This manual is intended for Storage Technology Corporation customer services personnel and authorized original equipment manufacturer (OEM) personnel. The manual provides instructions for preventive maintenance, troubleshooting, and removing and replacing field replaceable units. The instructions pertain primarily to the 4430 Library Management Unit (LMU), the 4410 or 9310/L5510 Library Storage Module (LSM), the 4420/L5520 Pass-thru Port (PTP), the 9320 Cartridge Exchange Mechanism (CEM), and the 4411 or 9311/L5511 Library Control Unit (LCU).

Organization
This book contains the following information: Chapter 1 General Information introduces the automated cartridge system (ACS) components. This chapter includes configurations, locations, motherboard designators, and specifications. Controls and Indicators describes displays, controls, and connectors for the LMU, LCU, LSM, and cartridge drive panels inside the LSM. Maintenance Procedures provides information preventive maintenance, interfaces, and initial power load (IPL). Power System Maintenance describes the power supplies for the LMU, LCU, and LSM. General Fault Isolation provides the fault isolation procedure and flowcharts to resolve problems in the LMU, LCU, and LSM. Removal and Replacement Procedures provides procedures to remove and replace field replaceable units in the LMU, LCU, and LSM. Equipment Restoral Procedures describes how to return the LMU, LCU, and LSM to normal operation after a maintenance operation.

Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7

Appendix A Principles of Operation describes how the components in the LMU, LCU, and LSM function. The cartridge subsystem library-related functions are also described. Appendix B 4430 LMU Terminal Control Unit Interface provides an overview of the LMU to terminal control unit interface. Glossary Index The Glossary defines new or special terms and abbreviations used in this publication. The Index assists in locating information in this publication.

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Alert Messages
Alert messages call your attention to information that is especially important or that has a unique relationship to the main text or graphic. Note: A note provides additional information that is of special interest. A note might point out exceptions to rules or procedures. A note usually, but not always, follows the information to which it pertains. CAUTION: A caution informs the reader of conditions that might result in damage to hardware, corruption of data, corruption of application software, or longterm health problems in people. A caution always precedes the information to which it pertains. WARNING: A warning alerts the reader to conditions that might result in injury or death. A warning always precedes the information to which it pertains.

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Conventions
Typographical conventions highlight special words, phrases, and actions used in this publication. Item Button Example
MENU

Description Physical buttons or switches, onscreen buttons, and softkeys appear in Helvetica font and in ALL CAPITAL letters. Important or emphasized words and phrases appear in italics. Filenames appear in Courier font. Indicators and LEDs appear with Initial Capital letters and in italics. Keyboard keys appear within brackets, in Helvetica font, with Initial Capital letters or as the key appears on the keyboard. Screen captures or messages appear in Courier font. Names of variables that require values assigned appear in italics. Pathnames appear in Courier font. Switch, jumper, and circuit breaker positions appear in default font and ALL CAPITAL letters.

Emphasized text Filenames Indicators, LEDs, and signs Keyboard keys

not or must dictionary.txt Open

[Y], [Enter] or [Ctrl+Alt+Delete]

Screen captures and messages Parameters and input Pathnames Positions for switches, jumpers, and circuit breakers URLs and hypertext links

downloading

Device = xx P:\Printshp\Pubs or home/gandalf/litdist ON

www.stortek.com/techpubs

Universal Resource Locator (URL) and hypertext links appear in blue text and can be underlined.

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Related Publications
Additional information is contained in the following publications, some of which are delivered with this product. Publication 9310/L5510/4410 LSM Nearline Automated Cartridge System Installation Manual (Models 4410, 4411, 4420, 4430, and 9320) Nearline Automated Cartridge System Installation Manual (Models 9310/L5510, 9311/L5511, 9320, 4420/L5520, and 4430) 4400 Product Information Card ACS Diagnostic System Users Guide (4430) Nearline ACS Hardware Operators Guide Nearline Automated Cartridge System IPC 4410 LSM Logic Assembly 4411 LCU Logic Assembly 4430 LMU Logic Assembly Cartridge Subsystems 4480 Cartridge Subsystem Maintenance Manual 4780 Cartridge Subsystem Maintenance Manual 9840 Service Reference Manual 9490 Service Manual SD-3 Service Manual 9840/T9840/T9940 Tape Drive Installation Manual 9840/T9840/T9940 Tape Drive Product Manual 9840/T9840/T9940 Tape Drive Service Reference Manual 9840/T9840/T9940 Tape Drive Users Reference Manual 9360 LSM 9360 LSM 9360, 9330, 9315, 9330 Automated Cartridge System Service Manual 9320 Cartridge Exchange Mechanism 9320 Cartridge Exchange Mechanism Installation Guide 95803 9869 99602 9031 95740 9635 9788 95879 95741 95740 95739 99606 9314 Part Number

9095 88555 9206 99600 89014 89009 89019

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Publication 9330/L5530 LMU 9330/L5530 Library Management Unit Service Manual 9330/L5530 Library Management Unit Installation Manual 9330/L5530 Library Management Unit Illustrated Parts Catalog ACS Diagnostic Guide for 9330/L5530/9315 LMU Central Support Remote Communication Installation Manual

Part Number 9865 9863 9870 9476 9483

Additional Information
StorageTek offers several methods for you to obtain additional information.

StorageTeks External Web Site


StorageTeks external Web site provides marketing, product, event, corporate, and service information. The external Web site is accessible to anyone with a Web browser and an Internet connection. The URL for the StorageTek external Web site is http://www.storagetek.com

Customer Resource Center


StorageTeks CRC is a Web site that enables members to resolve technical issues by searching code fixes and technical documentation. CRC membership entitles you to other proactive services, such as HIPER subscriptions, technical tips, answers to frequently asked questions, addenda to product documentation books, and online product support contact information. Customers who have a current warranty or a current maintenance service agreement may apply for membership by clicking on the Request Password button on the CRC home page. StorageTek employees may enter the CRC through PowerPort. The URL for the CRC is http://www.support.storagetek.com.

e-Partners Site
StorageTeks e-Partners site is a Web site that provides information about products, services, customer support, upcoming events, training programs, and sales tools to support StorageTeks e-Partners. Access to this site, beyond the e-Partners Login page, is restricted. On the e-Partners Login page, StorageTek employees and current partners who do not have access can request a login ID and password and prospective partners can apply to become StorageTek resellers. The URL for the e-Partners site is http://members.storagetek.com.

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Global Services Support Tools


StorageTeks Global Services Support Tools site provides tools that aid in the sales and support of StorageTeks products and services. This is an internal Web site for StorageTek employees. The URL for the Global Services Support Tools is http://wwssto.stortek.com

Documents on CD
Documents on CD (3106600xx) contains portable document format (PDF) files of StorageTeks hardware product publications. To order Documents on CD, contact your local Customer Services Logistics Depot. Documents on CD is only for StorageTek employees.

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This chapter covers three topics that are essential to all service representative activity: Your general safety Preventing electrostatic discharge (ESD) damage to equipment

Safety Precautions
WARNING: Potential injury: On-the-job safety is important; therefore, observe the following safety precautions while you are engaging in any maintenance activity. Failing to follow these precautions could result in serious injury. Remove all conductive jewelry, such as watches and rings, before you service powered-on equipment. Avoid electrical shock. Be careful when you work near power connectors and supplies. Power-off the equipment that is being serviced before you remove a field replaceable unit (FRU) or other component. Remember that dangerous voltages could still be present in some areas even though power is off. Ground all test equipment and power tools. Lift objects properly; read the information in Lifting Techniques (see below). Do not remove, cut, or relocate any floor tiles indiscriminately. Before you manipulate floor tiles, be sure that you understand the customers environment and receive the customers approval. Remember, each situation is different. Enforce good housekeeping practices in the equipment area to help prevent fire and accidents. Important things to investigate and to be aware of include the use of Halon gas, under-the-floor smoke detectors, and cables to other equipment installed nearby.

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Lifting Techniques
Lifting, regardless of how much or how little, can create serious back stress. If you follow these guidelines, you can reduce the risk of back injury: Do not twist your body to pick up something or to put it down. Twisting puts extreme pressure on your back, especially when you lift or carry objects. Instead of twisting, make the task two separate moves; first lift, and then use your feet to turn your body. Plan the lift: first examine the object and then determine how it will be lifted and where it will be placed. Choose the appropriate lifting technique. Examine the weight, size, location, frequency, and direction of the lift. Plan to avoid awkward postures, and determine if material-handling aids are needed. Place your feet shoulder-width apart, and place one foot a little behind the other. Keep your back straight because even light loads can significantly increase pressure on your spine when you lean forward. Whenever you can, grip the load with your whole hand, and use two hands. Carry objects at elbow height and close to your body. The farther away you hold an object, the more force it puts on your lower back. Lift with your legs instead of your back. Leg muscles are some of the strongest in the body. When you squat and lift with your legs, you can lift more weight safely. Alternate lifting tasks with tasks that are less stressful to the same muscles. This technique ensures that your muscles have some recovery time.

Shoulder, Elbow, Wrist, and Hand Safety


Follow these guidelines to minimize the possibility of injury to your shoulders, elbows, wrists, and hands. Work within your safety zonethe area between shoulder level and knuckle level of your lowered hands. You face less chance of injury when you work or lift in this area. Keep your elbows bent to keep loads close to your body and to decrease the amount of force necessary to do the job. If you use this posture, you will put less weight and pressure on your shoulder. Be sure to keep your wrists straight. Avoid bending, extending, or twisting your wrists for long periods of time. Do not use a pinch grip to lift large or heavy loads because the way you lift also can affect the tendons in your hand. When you grasp an object between your thumb and fingers, you put a lot of tension on hand and wrist tendons. Use both handsuse one for a while, and then use the otherto give them rest.

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Safety Practices
All maintenance personnel must use the following safety precautions to prevent injury to themselves and others, or damage to the equipment. Service representatives are responsible for making the system safe for themselves, other service representatives, and users. WARNING: Fatal injury: If manual access is required to the LSM, the individual closing the outer access door MUST first physically check the interior of the LSM and ensure that it is free of all personnel, tools, and parts before securing the door. Failure to do so could result in loss of life and/or destruction of equipment. Never work alone when hazardous conditions are present. Always disconnect AC and DC power when working near an exposed power supply. When you must work on equipment with exposed parts and circuitry, take the following precautions: Be sure that another person familiar with power-off controls is in the immediate vicinity. Do not wear jewelry. Use only insulated tools, keeping one hand in your pocket whenever possible. Avoid contacting a ground potential (for example, metal floors or machine frames); use a suitable rubber mat.

Wear safety glasses when soldering or using a power drill; when cleaning parts using solvents, sprays, cleaners, or chemicals; and when working in high-voltage areas or in the filter capacitor section of DC power supplies. Replace worn or broken tools and defective test equipment. Use only tools and test equipment approved by Storage Technology Corporation. Restore all safety signs, guards, shields, and other safety equipment, after completing maintenance. Do not attempt to defeat safety interlocks except as explicitly called for in the maintenance procedure. Restore all safety interlocks to their normal position before returning the equipment to the customer. Place removed covers in a safe, out-of-the-way area. Replace covers and ensure that they are locked by fastening the screws before returning the unit to the user. Always keep walk ways free of your tool box. Maintain good housekeeping while performing and after completing maintenance.

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Ensure that all signal or interface cables have been connected before returning the machine to the user. Cables must not be left with one end connected and the other accessible to the user. Follow established electrostatic discharge (ESD) grounding procedures when working with ESD sensitive components.

LSM Entry Procedure


Before entering the LSM, familiarize yourself with the location of the internal EPO switch on the door. When you prepare to enter the LSM, remove the LSM key ID plate, close the LAD, and latch it. This requirement makes it more difficult for someone to be locked inside the LSM. Take all spares of the plate with you inside the LSM to further ensure your safety. In the unlikely event that you do become locked inside an LSM, the ceiling lamps flash a warning before the robot moves. The robot initially sweeps back and forth slowly in search of any obstruction before starting normal high speed rotation. A firm push stops and shuts down the robot, allowing you to reach the door and exit. To gain entry to the LSM under normal operating conditions, have the operator vary the LSM offline to the operating system using the Modify command. Obtain the LSM key ID plate from the appropriate customer representative and unlock the access door. To gain entry to the LSM when the access door cannot be opened, see Emergency Entry (Standard Access Door) on page xlvi and Emergency Entry (Optional Access Door) on page xlvii. To prevent personal injury, three types of primary safety have been built into the system: Software interrupts (LAD open and door seated with HBO) +35 volts disconnected from the RE servos using interlock relays in the DC box and REI door interlock switch Motors disconnected and shorted.

Service personnel can enter the LSM when the DO NOT ENTER sign is illuminated by using the following procedure: 1. Issue a MODIFY LSM X OFFLINE. 2. Open the LAD to expose the key lock. Note: If Step 1 is skipped, opening the LAD still activates a switch to automatically cause a software interrupt and stop the robot. This causes any mounts in progress to abend. 3. Obtain the LSM key ID plate from the appropriate customer representative and unlock the access door. Pull on the latch handle to open the door. At this point, several events occur:

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a.

The door seated switch is deactivated by the locking pins.

b. Within 2 degrees of door rotation, voltage is removed from the REI servos and REI power is removed. (A service representative can override this switch to troubleshoot the remote electronics servos. It is located in the door frame header on the left-hand side accessible from the inside the LSM). A special tool is required to override the switch. When it is in the override position, +35 volts is supplied to the RE servos and the entry sign changes to read DO NOT ENTER. Voltages are present at the REI card cage area.) c. All motors are shorted together and disconnected from their amplifiers.

d. The theta servo main interlock switch and theta servo backup interlock switch are activated. These are serial switches, and either of these switches is sufficient to disconnect the theta motor from the theta power amplifier. The main switch cannot be overridden or accessed by tool or by hand. It removes the theta enable signal from the theta power amplifier card, thereby removing the voltage path to the theta motor. Both switches remove voltage from the theta motor by disabling the dynamic brake relay (DBR) on the theta power amplifier card in the LCU. e. f. The door HBO switch is activated, causing a software interrupt. The DO NOT ENTER sign illuminates.

4. Return the key lock to the locked position, remove the key, and close the LAD. This leaves the service personnel with the key in hand, changes the sign to SAFE TO ENTER, and jams the locking pins outward to prevent door closure (holds the door open beyond 2 degrees and the switches cannot be reactivated). With key in hand, the service personnel can safely enter the library. If Step 4 is skipped (the key is left in the door lock and LAD is not closed), the library is still safe to enter; however, this could lead to someone outside the library locking someone inside. If a person is locked inside, lights flash for 30 seconds while the software sets a 15-second delay. After 15 seconds, the robot slowly sweeps the area, in search of any obstruction. If the robot stops momentarily, it shuts down, allowing the person to reach the door and exit. During this time, the person can find the door and open it by using the interior latch and/or activating the EPO switch. Either of these actions stop any further power-up. (The inside door latch always allows someone to exit regardless of the exterior key position.) Also, during a normal initial power-up, the robot slowly sweeps the corridor in search of any obstruction. If the robot stops momentarily, it shuts down, allowing the person to reach the door and exit.

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Emergency Entry (Standard Access Door)


If a condition exists where the access door latch rods do not activate when the door handle is pulled, the following procedure allows a service representative access to the door latch mechanism inside the standard 21-cell CAP access door: 1. Issue a CAP enter request to the LSM. 2. When the CAP enter light illuminates and the CAP locked light extinguishes on the LSM access door, open the CAP door. 3. Turn the LCU operator panel power switch to OFF. 4. Remove the four screws in the CAP safety door upper cam plate. 5. Remove the four screws in the CAP safety door lower cam plate. 6. Move the upper and lower cam plates away from the CAP and remove the cam plates from the cams. This allows the safety door to move out of the way to gain access for working on the latching mechanism. 7. Locate and correct the problem to open the access door.

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Emergency Entry (Optional Access Door)


The following procedure provides a method to gain access into the LSM if a malfunction should occur that prevents the door from being opened by normal means. The cause might be a failure of the door latching mechanism prohibiting the access door latching rods from activating when the door handle is pulled. To gain access to the door latching mechanism, see page xxxix and page xl while perform the following steps: 1. If the priority cartridge access port (PCAP) can be opened by issuing an Enter request to the LSM, open the PCAP. 2. Have the operator modify the LSM offline using the Force option (otherwise, the LSM will not go offline with an enter is in progress). If the LSM cannot be put online to issue the Enter command, another option is to attach a Detached Diagnostic Device to the LMU, select the LSM, and run Test F60. When the PCAP unlocks, continue with the next step. 3. Turn the LCU operator panel power switch to OFF. 4. While supporting the viewing window panel, remove the two screws from the bottom of the viewing panel. CAUTION: The glass is loose inside the viewing panel and could fall out if care is not used. 5. Pull out at the bottom and downward to remove the viewing panel and glass from the access door. 6. Open the PCAP if it was not previously opened. Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. A small screwdriver blade placed into the left hole and pressed against the solenoid shaft unlocks the PCAP. If these holes are not present, perform the following steps to open the PCAP. 7. Insert a screwdriver with a 80-mm (3-in.) blade into the hole in the top of the PCAP latch cover as shown on page xxxix. 8. Position the screwdriver (approximately vertical) between the solenoid and the latch bar attached to the solenoid shaft as shown. 9. Gently move the screwdriver handle toward the front of the door to put pressure against the latch bar of the solenoid to unlock the latch assembly. 10. Pull outward on the latch handle to open the PCAP. 11. Disconnect the gas spring from the PCAP door. A small common blade screwdriver inserted under the locking device on the end of the gas spring will allow removal from the ball stud.

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12. Reach through the viewing window opening and locate the lower PCAP pivot pin. 13. Remove the hairpin clip securing the pivot pin in place. The pivot pin might drop inside the LSM and can be retrieved when the access is accomplished. 14. Locate and disconnect P/J931 on the top left-hand side of the PCAP (as viewed from the front of the PCAP). 15. Remove the Torx screw attaching the PCAP cable retainer to the access door (located below connector P931). 16. Remove the hairpin clip securing the top pivot pin. 17. Support the PCAP and remove the top pivot pin. 18. Remove the PCAP from the opening in the access door. 19. Locate and correct the problem to open the access door. 20. Retrieve any items dropped inside the LSM during the procedure.

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VIEWING PANEL SOLENOID ACCESS HOLE (SEE STEP 8 NOTE.)

PCAP LATCH COVER

OLD STYLE PCAP LATCH STEP 4: Remove the two screws from the bottom of the viewing panel. STEP 7: Insert screwdriver blade through hole in PCAP latch cover and position blade between solenoid and solenoid latch bar. Pull forward to unlock PCAP.

BALL STUD

LOCKING CLIP GAS SPRING

SCREWDRIVER BLADE

HAIRPIN CLIP

PIVOT PIN

STEP 11: Insert screwdriver blade under the locking clip and pry outward just enough to release the gas spring from the ball stud.

STEP 13: Remove hairpin clip securing the lower PCAP pivot pin.
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P/J931

CABLE RETAINER

PIVOT PIN HAIRPIN CLIP

STEP 14: Disconnect P/J931. STEP 15: Remove screw attaching cable retainer.

STEP 16: Remove hairpin clip. STEP 17: Support PCAP and remove top pivot pin.
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Access Door Restoral (Following Entry)


After the problem with the door has been corrected, use the following procedure to install all removed components onto the access door. 1. Position the lower pivot pin into the lower hole of the bezel and insert the hairpin clip through the middle slot in the pivot pin. 2. Position the upper pivot pin into the upper hole of the bezel and insert the hairpin clip through the bottom slot of the pivot pin. 3. Place the PCAP into the opening and align the lower holes of the PCAP and bezel. 4. Remove the hairpin clip while pressing the pivot pin into the hole in the PCAP. 5. Insert the hairpin clip into the lower slot of the pivot pin. 6. Align the upper hole of the PCAP with the upper hole in the bezel. 7. Remove the hairpin clip and reinsert it into the top slot of the pivot pin. 8. Connect PCAP cable P/J931. 9. Attach the PCAP cable retainer to the access door with the screw previously removed.

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10. Connect the gas spring to the PCAP ball stud by pressing the end onto the ball. 11. Attach the viewing window with glass by placing the tabs on the top of the viewing panel into the slots below the operator panel. 12. Press in at the bottom to align the holes and secure the viewing panel to the door with the two screws previously removed. 13. Close the PCAP. The PCAP must be closed before powering on the LCU to ensure the PCAP solenoid locks the PCAP.

LSM Components
To replace any component inside the LSM, use the following procedure to access the LSM: 1. Have the operator vary the LSM offline and open the lock access panel covering the keyslot and the door handle. If the LSM had not been varied offline, the robot inside the LSM immediately stops and the fingers retract when the lock access panel is opened. This prevents damaging the hand assembly if the LSM is illegally opened (the DO NOT OPEN sign is illuminated). 2. Obtain the LSM key ID plate from the appropriate customer representative, insert the key into the lock and unlock the door. The handle can now be pulled outward to open the door. Once opened, all servo motors are disabled and the DO NOT ENTER sign illuminates. 3. Close the handle and lock the door with the key. Then close and latch the lock on the access panel. The SAFE TO ENTER sign illuminates in the LSM. (In 4410 LSMs and 9310 LSMs without a lights bypass cable, the ceiling lights turn on at this point.) It also prevents the access door from being closed while someone is working inside the LSM. When the access door is open the following occurs: a. The theta motor is disconnected from the theta power amplifier using the theta dynamic break relay (DBR).

b. The +35 VDC bus voltage to the REI servos is disconnected from the REI servos via the REI servo interlock relay. c. The REI servo motors are disconnected from each servo amplifier using the DBRs.

d. Warning signs inside the LSM across from the door show that it is safe to enter the LSM. e. The lights inside the LSM come on automatically after the door is opened. The lights remain on for 20 seconds after the LSM door has been closed.

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f.

Turn the LCU operator panel power switch off. If the AC main circuit breaker is on and the LCU operator panel power switch is off, the entry sign inside the LSM remains lit. There is an emergency power-off (EPO) pushbutton switch inside the LSM. When activated, all AC power to the LCU and LSM is interrupted. The time-out of the LSM lights is not effected by the status of the EPO switch.

g.

h. A service representative can service the machine by overriding the REI interlock relay with a special tool. When this is done, the DO NOT ENTER signs inside the LSM illuminate and the +35 VDC is present at the REI servo cards. However, the REI servo motors will still be disconnected from the power amplifiers using the DBRs. WARNING: Fatal injury: Never override the DBRs.

Electrostatic Discharge (ESD) Damage Prevention


Anyone who handles ESD-sensitive components must be aware of the damage that ESD can cause to electronic components and must take the proper precautions to prevent it. Also, anyone who performs maintenance on StorageTek equipment must complete an ESD-basics course. CAUTION: Potential damage to equipment: Handle ESD-sensitive components only under ESD-protected conditions. To meet this requirement, always use the Field Service Grounding Kit (PN 4711) and always follow these ESD precautions and procedures when you are servicing StorageTek equipment or handling ESD-sensitive components.

ESD Precautions
Always take the following general precautions when you work with ESD-sensitive components: Wear ESD protection whenever you install, remove, maintain, or repair StorageTek equipment. Keep ESD-sensitive printed-circuit components in their ESD-protective packages until you have taken all ESD-preventive steps and you are ready to install the component. Do not allow anyone to touch or handle an unprotected ESD-sensitive component unless that person has taken all ESD precautions. Reinstall all equipment covers and close all equipment doors after you have completed the work.

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If the grounding-kit work surface has been exposed to temperatures above 66C (150F) or below 4.5C (40F), acclimate the work surface to room temperature before you unroll it. Immediately place any component that you have removed into an ESD-protective package. Keep the grounding-kit work surface clean. Note: To clean the work surface, use a mild detergent and water, and make sure that the surface is completely dry before you use it.

Periodically check the electrical resistance of the ground cord and the wrist-strap coil cord. Note: The ground cord should measure less than 1.2 M, and the coil cord should measure between 0.8 and 1.2 M . Repair or replace the cords if they no longer meet these requirements.

ESD-Protection Procedure
Remember that each customer environment is different. Address all the customers concerns before you work on any equipment.

Prepare the Work Area


1. Before you service the equipment, unfold the grounding-kit work surface completely and place it on a convenient surface. 2. Attach one end of the ground cord to the work surface; secure the snap fastener. Note: You will attach the free end in a later step. 3. Slip on an ESD wrist strap. Make sure that the strap is comfortable and makes contact with the entire circumference of your wrist. 4. Snap one end of the coil cord to the wrist band.

Access the Equipment


5. Carefully open the doors to the equipment or remove the covers from the equipment. Do not touch any internal components. CAUTION: Be sure that you are properly grounded before you touch any internal components. 6. Attach the free end of the coil cord to the most appropriate place: a. If you are working on components from a small piece of equipment, attach the free end of the coil cord to the grounding-kit work surface. In addition, be sure

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that you touch an unpainted metal surface on the equipment before you touch an internal component. b. If you are working on components from a large piece of equipment, attach the free end of the coil cord to a grounding jack or to an unpainted metal surface inside the equipment.

Replace Components
7. Remove the defective component and place it on the work surface. 8. Remove the replacement component from its ESD-protective package, and install the component in the equipment. 9. Place the defective component in the ESD-protective package.

Clean Up
10. Disconnect the ground cords from the equipment. 11. Reinstall all equipment covers and close all equipment doors. 12. Disconnect the coil cord from your wrist, and, if necessary, disconnect the ground cord from the work surface. 13. Properly store the work surface and the other Field Service Grounding Kit items.

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General Information

This chapter is an introduction to the StorageTek Automated Cartridge System (ACS), Models 44xx, 93xx, and L55xx. This chapter also includes a general description of the ACS, its characteristics, and configurations.

General Overview
The ACS (Figure 1-1 on page 1-2) consists of cartridges with attached transports; the mounting and dismounting of cartridges is automated. It is attached to single or multiple host systems through a customer-supplied terminal control unit. A library consists of one or more ACSs sharing common library control datasets. A library can support up to 256 ACSs, that is, library management units (LMUs) and the library storage modules (LSMs) attached to each LMU. Each LMU may be connected to only one ACS. The volumes and transports of a given ACS are managed through a single set of library control datasets. In a multi-host environment, the library control datasets are common to all hosts using the library. The host software component (HSC) within a host may communicate with and control more than one LMU, depending on the physical path connections. A typical enterprise configuration of the ACS is shown in Figure 1-2 on page 1-3. The ACS consists of five major components: HSC used for IBM hosts or ACSLS for open systems hosts LMUtwo for dual LMU configuration LSMs Library control units (LCUs) Cartridge subsystems or tape drives

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Figure 1-1. Automated Cartridge System

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Figure 1-2. Typical ACS Logical Configuration

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Host Software Component


The HSC resides in and executes on the host systems controlling the library. The HSC acts as the interface between a user application program or library management system (running under IBM MVS or VM operating systems) requesting tape processing and the LMU and LSMs that perform actual cartridge mounts and dismounts. The HSC maintains location and status records (library control datasets) of cartridges stored in the ACS; however, the HSC is not a cartridge management system. It does not maintain scratch pools or manage expiration dating. Rather, it provides for the automatic allocation of transports and automatic mounting of cartridges with a cartridge management system. HSC runs on any host that supports the IBM MVS/XA, VM/SP, or VM/XA System Facility operating systems. HSC can operate in a multi-host environment with up to 16 hosts sharing the library. All hosts using a particular library share the same library control datasets.

UNIX-Based Storage Server (4430 Attach)


For non-IBM host, the UNIX-based Storage Server connects an ACS through a workstation to multiple hosts. This connection to the server is at the 4430 LMU over RS-423 communication paths. Figure 1-3 on page 1-5 shows a typical configuration using a single 4430 LMU. The server contains code that carries out a role analogous to HSC. The 4430 LMU functional code is identical to the functional code used for IBM hosts. The Interface Processor Module (IPM, also known as the NN card) for the USS appears to the functional code as a normal 3270 IPM (LC card). The USS IPM sends and receives messages over the RS-423 to and from the server workstation. For information regarding how the 9330 or L5530 LMU connect to an open system server, please refer to the 9330/L5530 Library Management Unit Installation Manual, PN 9863, or the 9330/L5530 Library Management Unit Service Manual, PN 9865. Single server installations use one IPM, possibly with another as a redundant path. Dual servers uses two IPMs per server for a total of four IPMs maximum. The IPMs (NN cards) are installed in the 4430 LMU card cage in place of the LC cards in Locations E1 through H1 (see Figure 1-3 on page 1-5). The 4430 LMU serves as the LSM manager and provides the interfaces between hosts and LSMs. The 4430 LMU is capable of connecting from 1 to 16 hosts and up to 16 LSMs. The 4430 LMU interprets requests from the host and relays appropriate instructions to the correct LSM. Communications with hosts is through terminal control units for IBM hosts and server workstations for non-IBM hosts. Communication with LSMs is through a local area network. Figure 1-4 on page 1-8 shows the major components of the 4430 LMU inside the covers. The 4430 LMU motherboard, with card locations and connectors, is shown in Figure 1-5 on page 1-9.

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Figure 1-3. UNIX-based Storage Server Block Diagram (4430 LMU Attach)

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Library Storage Module


The LSM provides physical storage and automated retrieval and mounting of cartridges and tape path cleaning cartridges. It provides the storage area for approximately 6,000 cartridges, and attachments for a maximum of 16 transports (4410/9310), or eighty 9840/T9840/T9940 drives (9310 only). A maximum of eighty LTO drives can be attached to an L5510, or a mix of up to 80 LTO and 9840/T9840/T9940 drives can also be attached. An internal robot retrieves any cartridge in the LSM and delivers it to another cell, a transport/ drive, or to a pass-thru port (PTP)/cartridge exchange mechanism (CEM) connecting another LSM. The robot contains an optical system for identifying the optical character recognition (OCR) labels on the cartridges, and electro-mechanical mechanisms for selecting a cartridge and delivering it to the correct transport, cartridge access port (CAP), or PTP/CEM. The LCU is directed by the LMU; the LSM interprets cartridge movement and control instructions from the LMU and reports completion and status to the LMU. The LSM consists of the cartridge storage area that contains the cartridges and the physical cartridge handling system, and a LCU that manages the LSM. Figure 1-6 on page 1-10 (Model 4411 or 9311/L5511 LCU) illustrates the major components of the LCU. Figure 1-7 on page 1-11 shows the card locations and connectors on the 4411 and 9311/ L5511 LCU. Figure 1-8 on page 1-12 through Figure 1-11 show the major components of the LSM (Model 4410 and 9310/L5510). Figure 1-12 on page 1-16 illustrates the PLR and PLS/PLF card locations. Cartridge locations for the optional CAP door are shown in Figure 1-13 on page 1-17. The 4410 LSM REI motherboard is shown in Figure 1-14 on page 1-18. The connections for the PLR and PLS/PLF cards are shown in Figure 1-15 on page 1-19.

Cartridge Subsystems
Note: This manual describes the installation of the 4480 Cartridge Drive only. For information concerning the attachment of the 9490 (Timberline), SD-3 (Redwood), or other cartridge subsystems, consult the installation manuals for those particular units. The 4480 Cartridge Subsystem consists of Model M20 Control Units (CUs) and Model M22 and/or Model M24 Cartridge Drive units (CDs). A CU serves as the controller for up to eight transport units. It provides data path control and is used by the host operating system independent of the ACS.

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Library CDs feature Models M22 and M24 (two and four transport CDs respectively). They differ from manual CDs only in being attached to the LSM and controlled by the ACS rather than by an operator. The transports in the CD are independent and may be operated concurrently. They perform automatic tape threading, tape positioning, read/write functions, and status reporting to the CU. The LSM does mounting and dismounting of cartridges to the CD transports under direction of HSC and the LMU. Refer to the 4480 Cartridge Subsystem Maintenance Manual for information about the 4480 CU and CD.

Controls and Indicators


Controls and displays allow the operator to communicate with the HSC (through the operator's host console), LMU and LSM (through operator panels). Diagnostic and maintenance controls of the LMU and LSM are provided through local and remote maintenance computer interfaces (the LMU has local and remote; the LSM has remote).

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Figure 1-4. 4430 Library Management Unit

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Figure 1-5. 4430 LMU Motherboard

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Figure 1-6. 9311/4411 Library Control Unit

SERVICE PANEL

OPERATOR PANEL

VIEW A
I/O PANEL (UPPER)

CARD CAGE

FAN BOX REGULATOR ASSEMBLY (DX/MV CARD)

AIR/DUST FILTER

CSE SERVICE PANEL THETA SERVO CARD (LQ/PLQ CARD)

DC POWER SUPPLY

THETA BOX COVER TRANSFORMER

AC POWER SUPPLY

THETA AN D DX/MV FANS

I/O PANEL (LOWER) I/O PANEL C28029

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Figure 1-7. 9311/4411 LCU Motherboard

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Figure 1-8. Library Storage Module (Sheet 1 of 5)

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Figure 1-9. Library Storage Module (Sheet 2 of 5)

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Figure 1-10. Library Storage Module (Sheet 3 of 5)

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Figure 1-11. Library Storage Module4410 Robotics (Sheet 4 of 5)

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Figure 1-12. Library Storage Module9310/L5510 Robotics (Sheet 5 of 5)

Z MOTOR (2X)

THETA FLEX COIL HARNESS

PLR CARD

Z BELT (2X) PLS/PLF MODULE (2X) L5510 TURNTABLE ASSEMBLY (2X) THETA ARM ASSEMBLY

THETA MOTOR

THETA TURN COUNTER

9310 TURNTABLE ASSEMBLY (2X)

Z TRANSPORT (2X)

Z COLUMN (2X) Z FLEX CIRCUIT (2X)

THETA BASE

9310/L5510 ROBOTICS
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Figure 1-13. CAP Cartridge Locations

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Figure 1-14. 4410 REI Motherboard

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Figure 1-15. 9310 PLR/PLS/PLF Connectors

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ACS Configurations

ACS Configurations
The ACS supports a wide range of configurations. For example, variations in host-LMU connectivity, LMU-LSM networking, multiple LSM connectivity through PTP/CEMs, CD configurations within an LSM, outer wall arrangements, and cell populations within a wall are capable of configuration modifications, as explained below.

Configuration Guidelines
ACS configuration analysis must consider the following guidelines: A maximum of 16 transports per 4410/9310 LSM, minimum of two; or a maximum of eighty 9840/T9840/T9940 drives per 9310 LSM A maximum of eighty 9840/T9840/T9940 and LTO drives per L5510 LSM A maximum of four CDs per LSM, minimum of one Two or four transports per CD A maximum of either two master and two slave PTP/CEMs, or four slave PTP/CEMs per LSM LSMs may be configured in pure or mixed styles per LSM: Linear (side to side, each LSM attached to at most two others); maximum of 16 transports per LSM (4410/9310), or eighty 9840/T9840/ T9940 drives per 9310 LSM, or 80 LTO and 9840/T9840/T9940 drives per L5510 LSM Trefoil (dense pack or close hexagonal packing, each LSM attached to at most four others); limited to two packed rows to allow access to all LSMs; maximum of 16 transports (4410/9310), or eighty 9840/T9840/ T9940 drives (9310 only), or 80 LTO and 9840/T9840/T9940 drives (L5510 only) per LSM at either open or closed ends; maximum of eight transports (4410/9310) or forty 9840/T9840/T9940 drives (9310 only), or 40 LTO and 9840/T9840/T9940 drives (L5510 only), per enclosed LSM Orthogonal (square packing, each LSM attached to at most three others); limited to two packed rows to allow access to all LSMs; maximum of 16 transports (4410/9310), or eighty 9840/T9840/T9940 drives (9310 only), or 80 LTO and 9840/T9840/T9940 drives (L5510 only ), per LSM at ends or corners; maximum of eight transports, or forty 9840/T9840/ T9940 (9310 only ), or 40 LTO and 9840/T9840/T9940 drives (L5510 only), per enclosed LSM

Only those wall configurations that permit additional LSMs to be attached in the future (approved configurations) should be planned since wall reconfiguration labor costs are extremely high; PTP walls may be installed without the PTP/CEM for future growth ease

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The LCU must be attached to Wall 0 immediately to the left of the access door (Wall 11); also note that the inner walls have fixed location. Wall 10 is always a CD, or drive, wall Clearance for access door opening LCU operations and service clearances (front only) CD operations and service clearances (rear only) A maximum of 16 LSMs per LMU A maximum of 16 stations (terminal control unit interfaces) per LMU A maximum of 256 LMUs per library A maximum of 16 hosts per library The maximum number of cells per LSM depends on the wall configuration; Inner walls are fixed and their configuration cannot be changed.

ACS Configuration Examples


The following configuration examples include descriptions of single and multiple LSM configurations. They all conform to the configuration rules stated previously.

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Minimal LSM Configuration

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Figure 1-16 on page 1-23 depicts the single LSM configuration. Figure 1-16. Minimal LSM Configuration

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Dual LSM Configuration


Figure 1-17 on page 1-24 depicts a Dual LSM configuration with two hosts. Figure 1-17. Dual LSMs, Dual Hosts Configuration

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Three LSM Configurations


Figure 1-18 and Figure 1-19 on page 1-26 depict two separate options for configurations containing three LSMs. Figure 1-18. Triple LSMs, Linear Configuration

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Figure 1-19. Triple LSMs, Trefoil Configuration

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Orthogonal LSM Configuration


Figure 1-20 depicts a configuration containing six LSMs. Figure 1-20. Orthogonal LSM Configuration

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Maximum (Dense Pack) Configuration


Figure 1-21 on page 1-29 depicts the maximum configuration that can be placed under control of a single LMU.

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Figure 1-21. Maximum (Dense Pack) LSMs Configuration

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ExtendedStore LSM
An ExtendedStore LSM is an LSM configuration feature that provides cartridge storage space without the requirement of having a cartridge drive attached to the LSM. The hinged cartridge drive wall supporting the access door has a decorative cover installed instead of a CD. The LSM is connected through PTPs or CEMs to one or more LSMs with attached CDs. It does not increase the number of available cells in the LSM.

Cartridge Subsystems
Note: This manual describes only the installation of the 4480 subsystem. If your installation requires 9490 (Timberline), SD-3 (Redwood), or 9840/ T9840/T9940 drives, refer to those installation manuals for instructions on attachment to the LSM. To install LTO drives, refer to the 9741E Drive Cabinet Installation and Maintenance Manual, PN 95969 The StorageTek 4480 cartridge subsystem consists of 18-track CDs and CU. The size of the cartridge subsystem is somewhat flexible and limited primarily by the space available at each LSM in the configuration. Space always exists for two CDs (up to eight transports) and may exist for a maximum of four CDs (would require two terminal control units). For more information on the cartridge subsystem, refer to the 4480 Cartridge Subsystem documentation.

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Specifications
Table 1-1 through Table 1-6 on page 1-33 list the specifications for the 4400, 9310 and L5500 ACS. Table 1-1. Physical Dimensions LMU Height Width Depth (see Note 1) Weight (see Note 2) LCU Height Width Depth Weight LSM LSM Height Diameter (see Note 3) Weight (4410) Weight (9310) Notes: 1. With the side panels on. 2. With the front and rear panels on. 3. Across the flats of the wall. 2.35 m 3.25 m 3810 kg (loaded) 2446 kg unloaded) 3719 kg (loaded) 2249 kg (unloaded) 92.5 in. 128 in. 8400 lb (loaded) 5400 lb (unloaded) 8200 lb (loaded) 5200 lb (unloaded) 1.07 m 740 mm 810 mm 113 kg 1.61 m 400 mm 570 mm 136 kg 42 in. 29 in. 32 in. 250 lb 63.5 in. 15.6 in. 22.5 in. 300 lb

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Table 1-2. Altitude Operating Storage Shipping 0 to 3084 m (0 to +10 000 ft) 0 to 3084 m (0 to +10 000 ft) 0 to 15240 m (0 to +50 000 ft)

Note: The shipping environment must not exceed the limits of the storage environment for more than 10 days.

Table 1-3. Power Requirements LMU 200 VAC 10% 208 VAC +10%, -15% 220 VAC +10% 230 VAC 10% 240 VAC +10% Power consumption Operating line current Line frequencies Power connectors Single phase, 8 A rms (see Note) Single phase, 8 A rms (see Note) Single phase, 8 A rms (see Note) Single phase, 8 A rms (see Note) Single phase, 8 A rms (see Note) 0.6 kW (0.88 kVA) 4 A at 180 VAC (200 VAC nominal) Between 47 and 63 Hz US/Canada: RussellStoll 3720 male 3743/3913 female Others: None Single phase, 12 A rms (see Note) Single phase, 12 A rms (see Note) Single phase, 12 A rms (see Note) Single phase, 12 A rms (see Note) Single phase, 12 A rms (see Note) 1.1 kW (1.5 kVA) 8.4 A at 180 VAC (200 VAC nominal) Between 47 and 63 Hz

LCU/ LSM

200 VAC 10% 208 VAC +10%, -15% 220 VAC +10% 230 VAC 10% 240 VAC +10% Power consumption Operating line current Line frequencies

Note: 20 A power connector and branch circuit minimum rating for peak currents.

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Table 1-4. Operating Heat Output LMU LCU/LSM 2050 Btus/hr (517 kcal/hr) 3750 Btus/hr (945 kcal/hr)

Table 1-5. Temperature and Humidity Operating Temperature (ambient) Humidity Maximum wet bulb temperature (non-condensing) Thermal change (per hour) Shipping Temperature (ambient) Humidity Maximum wet bulb temperature (non-condensing) Thermal change (per hour) Storage Temperature (ambient) Humidity Maximum wet bulb temperature (non-condensing) Thermal change (per hour) +16C to +32C (+60F to +90F) 20% to 80% 25.6C (78F) Less than or equal to 5C (9F) -30.5C to +49C (-23F to +120F) 5% to 100% 26.6C (80F) Less than or equal to 15C (27F) +4.4C to +32C (+40F to +90F) 10% to 90% 26.6C (80F) Less than or equal to 15C (27F)

Table 1-6. Service Clearances LMU LSM LCU 810 mm (32 in.) front and rear 910 mm (36 in.) to open the access door 400 mm (15.6 in.) front

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Controls and Indicators


This chapter describes the control panels on the automated cartridge system (ACS) components. These components include the: 4430 Library Management Unit (LMU) 4411 and 9311/L5511 Library Control Unit (LCU) 4410 and 9310/L5510 Library Storage Module (LSM) 4480 Cartridge Drive

It describes the functions of the switches and indicators located on the panels of these ACS components. It only includes the operator panels of the CD that are mounted on the front panel of a stand-alone CD. Since the CD ships without the front door for an ACS component, these two panels are mounted inside the LSM. For information on the controls and indicators for the control unit and for those on the rear of the CD, refer to the 4480 Cartridge Subsystem Maintenance Manual, PN 99602. This chapter also includes illustrations of the AC and DC power supplies and tables describing the circuit breakers, fuses, plugs, and jacks associated with these power supplies. Also included are illustrations of motherboards and external cable connections for each of the components of the ACS.

Displays, Controls, and Connectors


Operator displays and controls consist of the host console for host software component (HSC) interaction, and the operator display and controls on the LMU and LSM. Service panels consisting of switches, indicators, and connectors located under covers, and those which are designed for service representative use only, are inaccessible to the operator (except for the LMUs and LCUs service panels). The figures and tables in the following paragraphs describe all of these displays, controls, and connectors for the ACS units. A red LED shows a problem, a yellow LED shows an abnormal operating condition, and a green LED shows a normal operating condition. Note: Card edge LEDs and test points for printed circuit boards in the LMU, LCU, and LSM are provided in Power-On Diagnostic Aids in Chapter 3, Maintenance Procedures.

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Library Management Unit

Library Management Unit


The library management unit (LMU) has two switches and five indicators. The control indicators and switches are described in the following sections. For information on the 9330/L5530 LMU please refer to the 9330/L5530 Library Management Unit Installation Manual, PN 9863, or the 9330/L5530 Library Management Unit Service Manual, PN 9865.

4430 LMU Operators Panel


The operators panel for the LMU (Figure 2-1 on page 2-3) is located on the front lefthand side of the LMU near the top of the unit. The panel is fully visible to the operator from the front of the unit. Table 2-1 describes the LMU operator panel controls and indicators. Table 2-1. 4430 LMU Operator Panel Control and Indicators Figure 2-1 Reference Number 1 Control/Indicator Name DC power indicator/ switch DC power switch Function Note: Earlier models use a rocker switch and indicator. When pressed, requests power to be supplied to or removed from the LMU under code control. DC power is on when the switch is pressed (on the top, and indicator on for rocker switch); DC power is off when the switch is pressed (on the bottom for rocker switch). Illuminates when DC power is supplied to the LMU. When pressed, immediately removes all AC/DC power from the LMU. Illuminates when the LMU microprocessor is functioning. Illuminates when the LMU microprocessor is not functioning (the watchdog timer timed out). Illuminates when the LMU is the Master LMU in a Dual LMU configuration. Shows a four-character display of intermediate initialization states and fault symptom codes. Illuminates when the software detected a hardware error; the status display contains a fault symptom code with additional information about the error.

DC power indicator 2 3 4 5 6 7
EPO switch

PROC ACTIVE indicator PROC INACTIVE indicator MASTER LMU indicator Status display SERVICE REQUIRED indicator

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Figure 2-1. 4430 LMU Operator Panel

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Library Management Unit

4430 LMU Service Panel


The LMU service panel (Figure 2-2 on page 2-5) is located on the front right-hand side of the LMU near the top of the unit. It is not normally visible, but it is accessible to the operator by opening the hinged door which covers the service panel. No special tool is required to open the door. Table 2-2 describes the LMU service panel controls, indicators, connectors, and floppy drives. Table 2-2. 4430 LMU Service Panel Components Figure 2-2 Reference Number 1 2 3 Component Name Function

LAN 0 ACTIVE indicator Illuminates when LAN 0 to the LCU is transferring data. LAN 0 ACTIVE indicator Illuminates when LAN 1 to the LCU is transferring data.
IPL switch

When momentarily pressed, causes a hardware reset and initiates the LMU power-on diagnostic tests, IPL procedures. Illuminates until IPL is complete. When pressed, attempts to continue through the errors detected during power-on, IPL, and functional procedures. For diagnostic procedures, an attempt is made to record the LMU state and any error code displayed in the status display. When pressed during functional operation, an LMU dump occurs.

IPL indicator 4
RESET switch

RESET indicator

Illuminates when the RESET switch is pressed and remains illuminated until the error condition is recorded. The alarm has been removed from the LMU by EC 27322. The RS-232C connector for attaching a StorageTek 392X Detached Diagnostic Device (or any properly configured dumb terminal). Use this drive to load the functional program or diagnostic program and to store error log information. It usually contains the functional floppy. Use this drive to load the functional program or diagnostic program and to store error log information. It usually contains the dump floppy.

5 6

ALARM RESET switch

MAINT. PORT connector

Floppy Drive 1

Floppy Drive 2

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Figure 2-2. 4430 LMU Service Panel

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4430 LMU I/O Interface Panel


The LMU I/O interface panel (Figure 2-3 on page 2-7) connects the external cables to the LMU. It is located in the lower right-hand side on the rear of the unit behind the door cover. The cables that attach to the panel are routed from beneath the raised computer room floor, through a floor panel cutout, to the bottom of the LMU. Table 2-3 describes the panel connectors. Table 2-3. 4430 LMU I/O Interface Panel Figure 2-3 Reference Number 1 Connector Name J476/J478 LAN 0 in/out connectors Function Use these connectors to connect the LCU to the LAN 0 daisy-chain. LAN 0 in and out BNCs are electrically connected. The LCU/LMU at the end of the daisy-chain must have a 50- terminator installed. Use these connectors to connect the LCU to the LAN 1 daisy-chain. LAN 0 in and out BNCs are electrically connected. The LCU/LMU at the end of the daisy-chain must have a 50- terminator installed. Use these connectors to connect up to 16 terminal CU cables (IPM 17 is a spare; it is not used). Use this port to enable the Customer Support Center hardware (modem or modem junction box) to connect to the LMU. Use these connectors to connect up to four UNIX-based workstation interface cables (non-IBM hosts). These connectors are not present on IBM host LMUs. Use this plate to provide EMI protection for IBM host-connected LMUs.

J477/J479 LAN 1 in/out connectors

J481J497 Host (3274) connectors J475 RDC PORT

J461J464 RS-423 IPM #1#4

EMI cover plate

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Figure 2-3. 4430 LMU I/O Interface Panel

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Library Control Unit


The library control unit (LCU) has five panels: Operator Service CSE service Signal I/O Power I/O

These panels are described in the following sections.

LCU Operator Panel


The LCU operator panel (Figure 2-4 on page 2-10) on the LCU is located on the front cover near the top of the unit. Table 2-4 describes the switches and indicators. Table 2-4. LCU Operator Panel Figure 2-4 Reference Number 1 Control/Indicator Name |/O (DC power) indicator/ switch Function Note: Earlier 4411 models use a rocker switch and indicator; later 4411 units and the 9311/L5511 use a pushbutton switch without an indicator. When pressed, requests power to be supplied to or removed from the LCU and LSM. DC power is on when the switch is pressed (on the top, and indicator is on for the rocker switch); off when the switch is pressed (on the bottom for rocker switch). Illuminates when DC power is supplied to the LCU. When pressed, immediately removes all power from the LCU and LSM, except for the keep alive voltage. Illuminates when the LSM is offline to all hosts. The LMU sets the state of this indicator through the Vary LSM Online/Offline software command. Illuminates when the LSM is online to the hosts. The LMU sets the state of this indicator through the Vary LSM Online/Offline software command.

DC power switch

DC power indicator 2
EPO switch

OFFLINE indicator

ONLINE indicator

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Table 2-4. LCU Operator Panel (Continued) Figure 2-4 Reference Number 5 Control/Indicator Name MAINT MODE indicator Function Illuminates when the LSM is in a state in which diagnostic commands can execute. This state exists when the LSM powers on to allow the wake-up diagnostic tests to execute or when software switch is activated by use of a 392X Detached Diagnostic Device. Illuminates when the LSM executes a command. Illuminates when the LCU watchdog timer has not been reset before the timer expired (the processor is not functioning). Illuminates when the LCU watchdog timer is in the normal state (the processor is functioning). Illuminates when smoke or fire detection sensors have removed all LCU/LSM power. Shows the four-character display with the appropriate error code when the SERVICE REQUIRED indicator is illuminated. When a failure generates multiple error codes, only the first error code displays. The software saves non-displayed error codes for examination through a 392X Detached Diagnostic Device or laptop computer. The display shows interim status during initialization (2XX, init-wrist, and so on). During normal operation, this display is blank. 11 SERVICE REQUIRED indicator Illuminates when the LSM must be serviced immediately and a service representative must be called.

6 7

LSM ACTIVE indicator PROC INACTIVE indicator

8 9 10

PROC ACTIVE indicator SMOKE DETECT indicator Status display

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Figure 2-4. 9311/L5511/4411 LCU Operator Panel

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LCU Service Panel


The LCU service panel (Figure 2-5 on page 2-12) is located near the top on the side cover. Table 2-5 describes the controls and indicators located on this panel. Table 2-5. LCU Service Panel Figure 2-5 Reference Number 1 2 3 Component Name LAN 0 ACTIVE indicator LAN 1 ACTIVE indicator
IPL switch

Function Illuminates when LAN 0 is transferring data. Illuminates when LAN 1 is transferring data. When momentarily pressed, causes a hardware reset and initiates IPL procedures. Illuminates when an IPL is initiated and remains illuminated until IPL completes. When pressed, attempts to continue through the errors detected during the power-on and IPL procedures. For diagnostic test purposes, an attempt is made to record the LCU state and any error code displayed in the status display. Illuminates when the RESET switch is pressed and remains illuminated until the error condition is recorded.

IPL indicator 4
RESET switch

RESET indicator

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Figure 2-5. LCU Service Panel

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LCU CSE Service Panel


The CSE service panel (Figure 2-6 on page 2-14) is located behind the front door cover and access to it requires a special tool. The panel is located below the motherboard on the left-hand side facing the front of the unit. Table 2-6 describes the components on this panel. Table 2-6. LCU CSE Service Panel Figure 2-6 Reference Number 1 2 Component Name
LSM ADDRESS switch

Function Use this thumb roller switch used to select the address (0F) of the LSM within an ACS. Use this connector to connect an ESD strap from the unit to the wrist of service personnel to prevent damage to components from electrostatic discharge. Use this RS-232C connector to attach a 392X Detached Diagnostic Device to communicate between the LMU and the LCU. This port has not and may never be activated. Use this RS-232C connector for engineering use, such as running the debugger routine to troubleshoot problems.

ESD ground connector

UTILITY P606 (maintenance) port

UTILITY P605 port

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Figure 2-6. LCU CSE Service Panel

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LCU I/O Panel


The I/O panel for the LCU (Figure 2-7 on page 2-16) is located inside the front door on the bottom right-hand side. There is a hinged door that lifts after the screw holding it in place is loosened. The external cables that attach to the bottom of the hinged door are routed beneath the raised computer room floor and through a cable cutout in floor section. Table 2-7 describes the panel connectors. Table 2-7. LCU I/O Panel Figure 2-7 Reference Number 1 Component Name LAN 0/1 IN J670/J672 connectors Function Use these connectors to connect the LAN 50- coaxial cables from either the LMU or the preceding LCU in a multiple LSM-configured ACS. Use these connectors to connect the LAN 50- coaxial cables to the next LCU in a multiple LSM-configured ACS. The last LCU must have terminators installed on these connectors. Use these connectors to route the camera on each hand assembly inside the LSM to an external video display terminal. These 75- connectors must be terminated if a monitor is not installed.

LAN 0/1 OUT J670/J672 connectors

VIDEO OUT 0 and 1 J678/J679 connectors

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Figure 2-7. LCU I/O Panel

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LCU/LSM Signal I/O Panel


The signal I/O panel (Figure 2-8 on page 2-18) for connecting the cables from the LSM to the LCU is located in the center upper two-thirds of the LSM side of the LCU frame. Access to the panel is from inside the LSM. Table 2-8 describes the panel. Table 2-8. LCU/LSM Signal I/O Panel Figure 2-8 Reference Number 1 Control/Indicator Name J620/J621 CAM 0/1 IN connectors J627/J629 PTP/CEM 0/1 SIGNAL connectors J628/J630 PTP/CEM MTR 0 and 1 connectors J623J626 CD 0, CD1, CD 2, and CD3 connectors Function Use these connectors to connect the two camera coaxial cables from the hand assemblies to the LCU. Use these connectors to connect the PTP/CEM signal cables from the LSM to the LCU (J628/J630). Use these connectors to connect the PTP/CEM motor cables from the LSM to the LCU (J628/J630). Use these connectors to connect one to four CD unit cables. J623 is connected to the CD that has transport Addresses 03, J624 for Addresses 47, J625 for 8B, and J626 for Addresses CF. The CDs are numbered clockwise Wall 0. The first CD met going CW from Wall 0 is CD 0 with Transport 0 on top and Transport 3 on the bottom. The second CD is CD 1 with Transport 4 on top and Transport 7 on the bottom, and so on. 5 J632 CAP SIGNAL connector Use this connector to connect the control and status signals from the LCU to the optional access door CAPs 0 and 1. It is not used with the standard 21-cell CAP door. Use this connector to connect the signal cable from the standard, 21-cell cartridge access port (CAP) or the optional door priority cartridge access port (PCAP) and the LSM access door. Use this connector to connect the remote electronics interface cable (from the LSM lower gusset connector bracket).

J631 CAP/DOOR connector

J622 REI connector

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PTP 0 SIGNAL

PTP 1 SIGNAL

Figure 2-8. LCU/LSM Signal I/O Panel

J628 PTP MTR 0

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J630 PTP MTR 1

J635
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J624 CD 1

J626 CD 3

J622 REI

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J627 J632 J629 J620 CAM 0 IN

Library Control Unit

I/O LSM
J621 CAM 1 IN

7
J631 CAP/DOOR

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LCU/LSM Power I/O Panel


The power I/O panel (Figure 2-9 on page 2-21) for connecting the cables from the LSM to the LCU is located at the lower left-hand side of the LCU frame. Access to the panel is from inside the LSM. Table 2-9 describes this panel. Table 2-9. LCU/LSM Power I/O Panel Figure 2-9 Reference Number 1 Control/Indicator Name Function J646 REI SERVO POWER connector Use this connector to connect the power cable that is routed up through the LCU wall and across the roof to the lower gusset connector bracket. Use this connector to connect the power cable that supplies power to the REI LS circuit card (4410) or PLR circuit card (9310/L5510). Use this connector to connect the dynamic brake relays in the LCU to the theta motor in the 4410 LSM. Note: This connector is not used in the 9310/ L5510; a jumper plug is installed in place of the cable. 4 J652 DOOR POWER connector Use this connector to connect power from the LCU MV card to the MZ card for the optional 80-cell CAP door. It is used on 4411-to-9311 conversions for the 9310/L5510 theta motor power (if the optional door is not attached and J653 is not available on the panel). Use this connector to connect the theta sensor cable that is routed from the theta turns counter on the theta motor. Use this connector to connect the power cable from the 4410 theta motor. Note: It is not used on the 9311/L5511. 7 J653 THETA MOTOR POWER, 9310 connector Use this connector to provide the 9311/L5511 connection for the power cable from the 9310/ L5510 theta motor. Note: It is not used on the 9311/L5511.

J647 REI REGULATOR POWER connector J651 THETA DBR connector

J648 THETA SENSORS connector J645 THETA MOTOR POWER, 4410 connector

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Table 2-9. LCU/LSM Power I/O Panel (Continued) Figure 2-9 Reference Number 8 Control/Indicator Name Function J650 INTERLOCKS connector Use this connector to connect to attach the cable that is routed to switches and relays, located in the entry door and threshold. The cable is routed up to the top of the LCU wall. Use this connector to connect the cable that is routed up to the roof section to supply power to the interior lights of the LSM. Use this connector to connect the cable from the theta arm limit switches that are mounted on the theta stop mechanism (4411) or the theta turns counter (9310/L5510).

J649 LIGHTS connector J812 EPO connector

10

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Figure 2-9. LCU/LSM Power I/O Panel

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Library Storage Module

Library Storage Module


The library storage module (LSM) has either a standard access door or an optional 80-cell cartridge access port (CAP) door. The operator panels for both types are described in the following sections. Note: The L5510 always uses the 80-cell CAP door.

LSM Standard Access Door and CAP Operator Panel


Located on the front of the LSM standard access door are the indicators and mechanisms (Figure 2-10 on page 2-24) to provide the service or operator personnel information and access to the 21-cell CAP and to the LSM using the access door. Table 2-11 provides information on this panel. Table 2-10. LSM Standard Access Door Operator Panel Figure 2-10 Reference Number 1 Control/Indicator Name Function CAP LOCKED indicator Illuminates when the CAP door is locked. The indicator turns off when either the CAP ENTER or CAP EJECT indicators illuminate. Illuminates when the operator is allowed to open the CAP door to enter cartridges. Illuminates when the operator is requested to open the CAP door to remove cartridges. Use this latch to open the CAP door if either the CAP ENTER or CAP EJECT indicator is illuminated. Use this latch to open the access door if the entry door lock is unlocked with the key. The DO NOT OPEN indicator turns off to prevent system abends. Press on the end of this latch and turn it 1/4-turn to open. The LSM must be offline and the DO NOT OPEN indicator must be off before opening the LAD. Use this latch to unlock the LSM access door latch handle. Use this switch to generate an interrupt to the functional software when the lock access door is opened. The software places the robotics in a safe position.

2 3 4

CAP ENTER indicator CAP EJECT indicator CAP door latch

LSM access door latch

Lock access door (LAD) latch

7 8

Entry door latch Lock access door (ALD) switch

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Table 2-10. LSM Standard Access Door Operator Panel (Continued) Figure 2-10 Reference Number 9 Control/Indicator Name Function DO NOT OPEN indicator Illuminates when the LSM is operational or is online.

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Figure 2-10. LSM Standard Door and CAP Operator Panel

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LSM Optional Access Door, CAPs and PCAP


The optional access door contains two CAPs and a priority CAP (PCAP), an operator display panel and viewing window. The LSM access door latch, entry door lock, lock access door switch, DO NOT OPEN indicator, and lock access door latch are identical to the ones on the standard door (see Table 2-11 on page 2-31). Figure 2-11 on page 2-26 shows the components on the outer side of the door.

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Figure 2-11. LSM Optional Access Door Latches/Display

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LSM Operator Warning Panel (inside LSM)


The LSM entrance warning panel (see Figure 2-12 on page 2-28) is located in the roof structure directly facing the doorway and clearly visible to anyone entering the LSM. It contains two signs that illuminate when certain interlock conditions exist. When the entrance door is closed, both of the signs are off. When the door is opened 2 degrees, the DO NOT ENTER sign illuminates. When the door is opened and the door latch rods are locked open with the key, the SAFE TO ENTER sign illuminates and the DO NOT ENTER sign turns off. If the door is locked open and the CSE override switch is activated, the SAFE TO ENTER sign turns off and the DO NOT ENTER sign illuminates.

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Figure 2-12. LSM Operator Warning Panel

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LSM Entrance Door EPO Switch


The emergency power off (EPO) switch for the LSM is located inside the entrance door just below the CAP (see Figure 2-13 on page 2-30). It is in the same location on the optional door as on the standard door. It is a round red button, that, if pressed inward toward the door, immediately performs an EPO to the LCU and removes all power from the LSM.

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Figure 2-13. LSM Entrance Door EPO Switch

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4480 Cartridge Subsystem

4480 Cartridge Subsystem


The following sections describe the unique display panels and switches for the 4480 cartridge subsystems.

4480 Cartridge Drive Control and Display Panels


Each CD attached to the LSM includes a manual mode operator display panel and a control panel (Figure 2-14 on page 2-33). Table 2-11 describes the components on these panels. These two panels are accessible only from inside the LSM and are operative only during manual cartridge operation. The display panels for the transports are mounted above the top transport on the air box cover. In units that use the DD cards (rather than the DDM card), the top display corresponds to the top transport, the bottom display to the lowest transport, and so on. In units that use the DDM card, the upper left corner of the display corresponds to Transport 0, the upper right corner to Transport 1, the lower left corner to Transport 2, and the lower right corner to Transport 3. During normal operation, the display blanks. The control panel is located to the right of the transport opening and mounted on the air box for each of the installed transports. Table 2-11. 4480 Cartridge Drive/Operator Panel Controls and Indicators Figure 2-14 Reference Number 1 Control/Indicator Name SELECT indicator Function Illuminates when the CU communicates with the CD during manual operation. The SELECT indicator is turned off during normal LSM operation. Illuminates when the operator must perform a task to permit CD operations to continue. The OPERATOR indicator is turned off during normal operation. Illuminates when, in the manual mode of LSM operation, the transport is offline to the CU. Illuminates when transport conditions (NT RDY F, EOT, ERASING), transport error information (CHK XX), and volume serial information (12345, M 123456, K 123456, and so on). The display is blank during normal LSM operation.

OPERATOR indicator

OFFLINE indicator

Alphanumeric display

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Table 2-11. 4480 Cartridge Drive/Operator Panel Controls and Indicators Figure 2-14 Reference Number 5 Control/Indicator Name
REWIND switch

Function Press this momentary switch rewinds the tape to the beginning of tape if the READY switch is in the not ready position. Pressing the REWIND switch again and holding it down for several seconds resets any hold-off load and unblanks the display. Pressing this momentary switch rewinds the tape to the beginning of tape and ejects the cartridge for removal by the operator if the READY switch is in the not ready position. Pressing this alternate-action switch to the ready position enables the transport to read data from and write data to the tape and disables the REWIND and UNLOAD switches. The READY switch must be in the ready position for normal LSM operations. Pressing the READY switch to the not ready position disables the read/write operation and enables the REWIND and UNLOAD switches to perform their functions.

UNLOAD switch

READY switch

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Figure 2-14. Cartridge Drive Operator Panels

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Maintenance Procedures

This chapter provides service representatives with information and procedures for field maintenance of the automated cartridge system (ACS) for the models shown in Table 3-1. Table 3-1. Models Supported in this Manual 44xx Automated Cartridge System 4410 Library Storage Module (LSM) 4411 Library Control Unit (LCU) 4420 Pass-thru Port (PTP) 4430 Library Management Unit (LMU) 93xx/L55xx Automated Cartridge System 9310/L5510 Library Storage Module (LSM) 9311/L5511 Library Control Unit (LCU) 4420/L5520 Pass-thru Port (PTP) 4430 Library Management Unit (LMU)

Areas described in this chapter include preventive maintenance, power-on diagnostic aids, 3270 wrap, IPM/terminal control unit status check, channel status tracing, LCU-CD interface problems, and IPL. Refer to the 4480 Cartridge Subsystem Maintenance Manual (PN 99602) for the maintenance procedures for the control unit (CU) and cartridge drive (CD). Refer to the ACS Diagnostic System Users Guide (PN 88555) for the procedures (tests, environments) to diagnose the LMU, LSM, and LCU. WARNING: Bodily harm: Be sure to follow the safety precautions in Safety on page xli before proceeding with any preventive maintenance procedure in this chapter.

Preventive Maintenance
This section describes monthly, semiannual, Safety Practices on page xliii and annual maintenance to perform for the LSM. See Safety Practices and LSM Entry Procedure on page xliv and the removal and replacement procedures (if needed) in Chapter 6, Removal and Replacement Procedures.

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Tools, Lubricants, and Parts Required


Table 3-2 shows the tools, lubricants, and parts that must be on hand before performing preventive maintenance on the LSM. Table 3-2. Tools, Lubricants, and Parts Tools 3/8-in. drive torque wrench 1/4-in. drive to Torx tip adapter T-30, 25, and 15 Torx bits 1/2-in. x 3/8-in. socket Long, thin screwdriver 1-in. foam brush Z-channel lock pins (4400 only) Array target paint (white, PN 4107084xx) Lubricants Apiezon-L (PN 4107447xx) (see Note 1) 4420 PTP belt (PN 4103009xx) 4420 PTP slider springs (PN 4103022xx) Turntable belt4410 (PN 4102832xx) Counterweight cable4410 (PN 4106474xx) (see Note 2) CAP safety doorstandard access door only (PN 4103246xx) Precise light bulbs4410 (PN 41028232xx) Dextron II transmission fluid4410 (purchase locally) Notes: 1. Apiezon-L contains Isopar-L solvent, which is a non-CFC solvent. 2. Required replacement on six-month preventive maintenance; one each needed per 4410 LSM with leadscrew-driven Z channel. White grease (PN 3800016036) Ceiling lights (PN 4103131xx) Roll belt (PN 4103022xx) Z motor belt4410 (PN 4102831xx) Kevlar counterweight belt4410 (PN 4108143xx) Safety door springsstandard access door only (PN 4103955xx) Door entry sign lights (PN 10079030) Pre-loaded grease gun (PN 4109455xx)4410 Z-channel application Parts 1/4-in. drive torque wrench Torx handle 9/16-in. x 3/8-in. socket 3-in. x 3/8-in. extension Small Phillips screwdriver 3/16-in. Allen wrench Lint-free cloth

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Monthly Maintenance
Check the following items monthly. Cartridge access port (CAP) subassembly (21-cell CAP) Check the CAP targets for chipping and damage. The CAP arrays, as required, for re-painting, removal, or replacement

Semi-Annual Maintenance
Note: At least one day before performing this preventive maintenance (PM), dump the error log using the Analyze function. Determine if any errors must be addressed during the PM. Determine the parts or equipment that might be needed and have them available at the PM time. The following items should be checked every six months and adjusted, lubricated, or replaced if necessary.

REI Card Cage Fans (4410 Only)


Check for proper operation of the cooling fans on the REI card cage. Replace the fan(s) as required.

EPO Switches
Note: Do not use CB1 or CB2 instead of the |/O (DC power) switch to turn the LCU on and off. Always turn the |/O (DC power) switch to OFF before resetting CB1 or CB2. Check the EPO system for an operable condition by using the following procedure: 1. Place the |/O (DC power) switch in the ON position. 2. Press the EPO switch inside the LSM access door. The LSM performs an emergency power-off (EPO). 3. Place the |/O (DC power) switch to the OFF position. 4. Reset the LSM with the EPO reset switch on the LCU AC power supply. 5. Turn the AC box CB2 on. 6. Turn the |/O (DC power) switch to the ON position. 7. Press the EPO switch on the LCU front panel. The LSM performs an EPO. 8. Repeat Steps 3 through 6.

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9. Disconnect the two-pin connector P857 (Figure 3-1 on page 3-5) from the smoke detector on the roof nearest the access door. Connect a jumper lead across the two pins in the connector. The power goes off. 10. Connect P857 to the smoke detector, and reset the EPO condition as stated previously. 11. Disconnect the two-pin connector P857 (from the smoke detector on the roof farthest from the door). 12. Connect a jumper lead across the two pins in the connector. The power goes off. 13. Connect P857 to the smoke detector and reset the EPO condition as stated previously. 14. Close and lock the LSM access door. 15. IPL the LSM.

Access Door
1. Check the door for binding and ease of operation. 2. Check the warning signs and ceiling lights: a. Before the access door is opened (the lock access door [LAD] is in any position), the warning sign is not illuminated.

b. Open the door, leaving the key in the LAD. The DO NOT ENTER sign illuminates. c. Remove the key and close the LAD. The SAFE TO ENTER sign illuminates. Note: In 9310 LSMs with a lights bypass cable (PN 3084770xx), ceiling lights are on at all times; otherwise, the ceiling lights should not come on until Step 2c.

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Figure 3-1. LSM Smoke Detector Pin-Out Locations

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21-Cell Cartridge Access Port Subassembly


1. Inspect the hinges for ease and smoothness of movement. 2. Lubricate using the following procedure: a. Open the CAP by pressing the pin until it clears the lockcap solenoid bracket.

b. Press the latch CAP push bar. c. Place a spacer between the inner door latch subassembly and the CAP to support the CAP.

d. Loosen the two screws on the lower hinge support. e. f. g. Slide the hinge down. Apply lubricant, PN 10305009, with a foam swab. Move the hinge support up and tighten.

h. Repeat with the upper hinge block. i. Remove the spacer.

3. Check the safety door springs by closing the CAP door. If the safety door advances ahead of the CAP and does not jam, the springs are fine. If not, the springs have lost their tension. Replace each spring, using the following procedure (see also Figure 3-2 on page 3-8). 1) Open the CAP by pressing the pin until it clears the lockcap solenoid bracket. 2) Press the latch CAP push bar. 3) Remove the retaining ring from the groove in the bottom of the torque adjuster. 4) Remove the two nuts from the hinge support and remove the support. 5) Pull the bearing and the spring from the torque adjuster. 6) Insert the new spring up into the torque adjuster, aligning the top groove. Insert the same bearing under the spring and insert the retaining ring into the groove on the bottom of the torque adjuster. 7) Attach the hinge support to the safety door with two nuts.

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4. Adjust the torque adjuster in the hinge supports one turn to provide the proper tension on the safety door, using the following procedure: a. Remove the socket head screw from each torque adjuster.

b. Use two #6 screws or center punches to turn the torque adjuster clockwise one turn. c. Perform one of the following: If the older type hinge support is installed, hold the torque adjuster in this position and have someone from outside the access door insert the socket head screw into the threaded hole just clockwise of the CAP hinge block. Leave the screw approximately 6.35 mm (0.25 in.) out of the torque adjuster. This portion of the screw rests against the access door surface when the torque adjuster is released, providing the proper spring tension. If the newer type hinge support is installed, insert the socket head cap screw through the hole in the top of the hinge support and thread it into the torque adjuster. Leave the screw approximately 3.18 mm (1/8 in.) out of the torque adjuster.

5. Check the safety door cam followers for damage, and replace, if necessary. 6. Check that the proximity sensor (when installed correctly) has 1.6 mm (1/16 in.) gap to the bottom plate of the CAP door.

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Figure 3-2. Safety Door Spring

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Theta Harmonic Drive Assembly (4410)


1. Re-torque the 9/16-in. nuts to 33.9 Nm (300 in.-lb), in a star pattern. 2. Re-torque the T30 screws to 6.7 Nm (60 in.-lb) in a star pattern. 3. Check for automatic transmission fluid leaks at the bottom of the base and on the cables from the theta motor assembly using the following procedure: a. Remove the breather vent from the center of the theta drive plate with a hex wrench.

b. Insert a 100-mm (4-in.) Phillips-head screwdriver into the motor shaft until the end of the blade bottoms out. c. Remove and inspect the blade. If any fluid at all is there, the fluid level is fine and the breather vent can be installed and tightened. If no fluid is there, proceed with Step 3d.

d. Tilt the screwdriver at a 30-degree angle from the motor shaft and insert it beside the shaft until the handle hits the theta drive plate. Remove and inspect the bladeif any fluid at all is there, the fluid level is fine and the breather vent can be installed and tightened. If fluid is not there, proceed with Step 3e. e. f. Check for leaks by inspecting the cables and the bottom of the theta base by shining a light down inside the theta screen on top of the plate. If a leak is found, replace the theta drive assembly. If leak is not found, add a small amount of automatic transmission fluid (ATF), 100 ml at a time, and use the preceding screwdriver method to check for sufficient amount. Repeat, if necessary. Note: If the amount of ATF added is more than 6.4 mm (0.25 in.) of fluid on the screwdriver blade, ATF leaks out of the theta cover because of the splash created by theta movement. g. Install and tighten the breather vent.

Theta Arm/Theta Arm Stop Assembly (Gear-Driven)


1. Do not lubricate the top gear on the stop assembly or the gear on the theta arm. 2. Check the theta arm stop assembly for hard crash damage, using the following procedure: a. Remove the top gear cover and inspect the retaining ring for deformation. If the deformation is excessive, remove the retaining ring and top gear.

b. Lift the leadscrew shaft up and down. If the motion is greater than 1.6 mm (0.063 in.), replace the entire theta arm stop assembly.

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3. Check the leadscrew for rust, and ease and smoothness of movement. Lubricate using the following procedure: Note: The Apiezon-L lubricant, located in the LSM Installation Tool Kit, is a low vapor pressure grease dissolved in a non-CFC solvent (Isopar-L). The solvent serves as a carrier for ease of application only. After application, the solvent quickly evaporates, leaving a thin film of the Apiezon-L. If the recently lubricated surface appears dry, the solvent has evaporated, leaving the lubricant behind. Also, shake the container well before use and keep the lid on the bottle whenever the lubricant is not being used. a. Remove the housing cover.

b. Move the theta arm to its limit switch to expose a couple of threads and lubricate. c. Apply the Apiezon-L lubricant to the leadscrew with the lubricant brush located in the LSM Installation Tool Kit.

4. Move the theta arm to the other limit and lubricate as described. 5. Rotate the top gear to make sure that all areas are covered. 6. Install the housing cover.

Theta Arm/Theta Arm Stop Assembly (New Style)


This procedure applies to the 4410 LSM only. Note: The new style theta crash stop was released starting with 4410, Serial Number 960. 1. Check the new style crash stop for scraping or scoring the outer surface of the theta ring during normal operation. 2. To identify this problem, look at the theta ring located at the base of the theta arm (all of the rings have been anodized yellow in color and when scoring occurs the aluminum will be revealed), and inspect for scrapes. Note: Aluminum filings may also be present on the floor around the theta base near the mounting area of the crash stop. 3. Correct any problem discovered during inspection.

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Z Channel Assembly (Leadscrew-Driven)


This procedure applies to the 4410 LSM only. 1. Check the linear shafts of the Z arm and counterweight plate for rust or grooves, plus ease and smoothness of movement. Replace the Z channel assembly if necessary. Lubricate using the following procedure: Note: The Apiezon-L lubricant, located in the LSM Installation Tool Kit, is a low vapor pressure grease dissolved in a non-CFC solvent (Isopar-L). The solvent serves as a carrier for ease of application only. After application, the solvent quickly evaporates, leaving a thin film of the Apiezon-L. If the recently lubricated surface appears dry, the solvent has evaporated, leaving the lubricant behind. Also, shake the container well before use and keep the lid on the bottle whenever the lubricant is not being used. CAUTION: Bearing damage: If the linear shafts are dirty (accumulation of dust, and so on) clean the shafts with a clean lint-free cloth and isopropyl alcohol before lubrication. Do not get any alcohol in the bearings as this can cause other problems. a. Apply Apiezon-L lubricant onto the shafts with the lubricant brush located in the LSM Installation Tool Kit. Allow the lubricant to run down through the linear bearings.

b. Manually move the Z arm up and down the freshly lubricated areas of the shaft to make sure all exposed surfaces are covered. 2. Check the leadscrew for rust plus ease and smoothness of movement. Replace if necessary. Lubricate using the Apiezon-L lubricant. Note: If the leadscrew is dirty (accumulation of dust, and so on) clean the leadscrew with a clean lint-free cloth and isopropyl alcohol before lubrication. Do not get any alcohol in the bearings as this can cause other problems. Lubricate using the following procedure: a. Apply the Apiezon-L lubricant to the leadscrew (including the area just above the ballnut to lubricate the balls) with the lubricant brush.

b. Manually move the Z arm up and down, turning the leadscrew, to make sure all areas are covered. c. The top and bottom bearings are permanently lubricated. Check them for ease and smoothness of movement and replace, if necessary.

d. Check the Z motor belt for debris and wear (leadscrew-style Z channels only). Replace the belt, if necessary.

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e.

Check the Z motor belt tension. Loosen all four screws securing the motor mounting plate, observe, and then retighten for auto spring adjustment. The counterweight pulley bearings are permanently lubricated. Check for debris and shaft movement out of the bracket. Check for ease and smoothness of movement and replace, if necessary. Remove any debris from the pulley channels. Check the counterweight plate bearings and Z arm plate bearings for rust or grooves on the shafts, plus ease and smoothness of movement. Replace the bearings, if necessary.

f.

g.

h. Remove and replace the counterweight cable.

Z Channel Assembly (Belt-Driven)


This procedure applies to the 4410 LSM only. 1. Check the Kevlar belt for cracks. Replace, as necessary. 2. Apply one pump of grease from the grease gun to each of the four fittings in the linear bearings for the Z arm and counterweight. 3. Cycle the Z arm to both top and bottom extremes several times. 4. Using a lint-free cloth, wipe the excess grease from the top and bottom of the linear bearing rails for the Z arm and counterweights.

Z Belt and Z Flex Guide (9310/L5510)


This inspection procedure applies to the 9310 and L5510 only. 1. Verify the smooth movement of the Z belt through the full range of movement on both Z columns 2. Verify the smooth movement of the Z Flex Guide through the full range of movement on both Z columns. Note: Popping, crinkling noises, or excessive lateral motion are precursors to flex guide failure, which will damage the Z Flex Cable over time. 3. If a defective guide is suspected, remove the guide and inspect the Z Flex cable for signs of damage. 4. Replace the Z Flex Guide and Z Flex Cable if damage is found.

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Turntable Assembly (4410 Only)


To check the turntable motor belt tension: 1. Loosen all four screws securing the motor mounting plate, observe, and then retighten for auto spring adjustment. 2. Check the turntable motor belt for wear. Replace, if necessary. 3. Check the spindle bearing for free movement; no roughness is expected. Replace, if necessary. 4. Check the coaxial flex cables for wear or cracking. Replace, if necessary.

Hand Assembly (4410 Only)


CAUTION: Hand damage: This hand does not require any lubrication in the field. The lubricant has been added during the manufacturing process. Do not lubricate any component on the hand assembly. 1. Clean the linear shafts with a clean dry lint-free cloth. Do not lubricate the linear shafts after cleaning them. 2. Check the linear shafts for rust or grooves, plus ease and smoothness of movement. Replace the hand assembly if necessary. Note: Some resistance will be experienced because of the reach motor, bearings, and leadscrew nut. 3. Check the roll belt tension. Loosen, observe, and tighten the mounting bracket for auto spring adjustment. 4. If the hand has a PN 4102752xx-level MD card, check the rework wires on circuit side for breakage or wear. Replace, if necessary. 5. Check the roll-flat-flex and roll-coaxial-flex cables for damage and cracking. Replace the cables as necessary. 6. Check the gripper assembly for bent or loose fingers. Replace the gripper assembly as necessary. 7. Check the MK card bracket and verify that it has not been bent and that reach carriage flags are centered in the sensors during normal motion. 8. Check that the connector P783 on the MK card is well-seated. 9. Check the plunger flags, verifying they do not hit the MA card sensors or the reach motor power cable wires. Adjust as required. 10. Remove and reseat both lamps on both hands. Ensure that the lamps have a firm connection with the lamp socket.

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Camera
1. The lens is preset and pinned from movement in manufacturing; no adjustment is needed. 2. Wipe the lens with a clean, lint-free cloth.

4420 PTP Assembly


1. Check the leadscrew for rust or grooves, plus ease and smoothness of movement. Replace, if necessary. Note: If the leadscrew is dirty (accumulation of dust, and so on) clean the leadscrew with a clean lint-free cloth and isopropyl alcohol. Do not get any alcohol in the bearings as this will cause other problems. CAUTION: Leadscrew damage: Do not put any lubricant on the PTP leadscrew. It is coated with teflon, and lubricant will cause it to bind. 2. Check the linear shafts for rust or grooves, plus ease and smoothness of movement. Replace, if necessary. 3. Remove the belt cover on the master side of the PTP by removing the three #10 Torx screws. 4. Rotate the leadscrew pulley until the array is in the slave side. 5. If not already removed, remove the belt cover on the master side of the PTP by removing the three #10 Torx screws. 6. Check the belt for wear and slippage. Replace, if necessary. 7. Check the slider springs on the nut support on the support shaft. Replace, if necessary. 8. Check the cartridge arrays for wobble, which must not exceed 1.58 mm (0.12 in.) when fully extended in master or slave side. If wobble is more than allowed, replace the ball bushing/shaft.

Long Initialization
1. Perform a long initialization using the procedure described in the Automated Cartridge System Diagnostic System Users Guide, PN 88555. 2. After the long initialization completes, look at the LSM status in the Utility (UTL) environment by entering ST DE=x where x is the LSM number. Verify that all components are operational. 3. If code is at Level 2.3 or lower, perform a second IPL by pressing the IPL switch on the LCU.

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Diagnostic Tests
Run diagnostic tests (suggested minimums are Tests 820 and E20) using the XR(un) parameter. Refer to the Automated Cartridge System Diagnostic System Users Guide, PN 88555, for information and procedures to use.

Modify LSM Online


Have the operator return the LSM to an online state using the Modify LSM Online/Offline command. Refer to the appropriate software operators guide for the command syntax and console messages.

System Level Checks Using HSC Commands


1. Eject and enter a cartridge using the CAP on the LSM to verify CAP operations. Check the CAP to verify that it holds the door closed when it is in a locked state. 2. Exercise PTP/CEMs to verify operations by ejecting cartridge from another LSM (if applicable).

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Annual Maintenance
The items below must be replaced every 12 months.

Theta Counter Shear Pin (9310/L5510 Only)


Refer to Figure 3-3 on page 3-17 while performing the following steps to remove and replace the theta counter shear pin, PN 3084316xx.

Removal
1. See LSM Entry Procedure on page xliv 2. Open the inner door. 3. Remove the screw attaching the shear pin clamp to the theta turntable. 4. Remove the theta turns counter shear pin from the theta turntable by pushing the shear pin from the bottom.

Replacement
1. Insert the theta turns counter shear pin into the theta turntable with the pin pointing down. 2. Attach the shear pin clamp over the shear pin and secure with the screw previously removed. Torque the screw to 3 Nm (26 in.-lb). 3. Close and secure the inner door. Check the alignment using the wall alignment fixture. 4. Torque the screws to a value of 32.5 to 38 Nm (288 to 336 in.-lb). 5. See Chapter 7, Equipment Restoral Procedures.

Smoke Detectors
For a non-Halon system, remove and replace both detectors, returning the old detectors to the plant for recertification. Note: If you are removing an ionization smoke detector, replace it with a photo-electric smoke detector. For a Halon system, maintenance is the responsibility of the Halon system installer, not the StorageTek service representative.

Bulbs (4410 Only)


Replace the precise light bulbs on each hand assembly. Be sure that the lamps are seated firmly and that a solid lamp connection exists.

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Figure 3-3. Theta Counter Shear Pin (9310/L5510 Only)

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Power-On Diagnostic Aids


A four-digit display on the LMU and LCU front panel displays any faults. If the panel is non-functioning, there are card edge indicators and test points located on several of the printed circuit cards in the ACS. Figure 3-4 on page 3-21 through Figure 3-7 on page 3-37 show the card locations while Table 3-3 on page 3-18 through Table 3-6 on page 3-35 provide a description of indicators and test points. Test-point terminals are one or more 10-pin header connectors with numbering of pins from top to bottom. Note: Because of different compatibility levels of cards, some indicators and test points might differ from those shown in this manual, however, the major indicators and test points should be available and identified on all cards. Those shown in this manual are for the latest, EC-released printed circuit cards. Table 3-3. 4430 LMU Card Cage Indicators Figure 3-4 Reference Number 1 Indicator/Test Point Name Function IPM Cards Green LED The 3270 Interface is polling the LMU and the LMU is responding correctly. The cable is attached to the terminal control unit port and the terminal control unit is operating. 2 Red LEDs If not polling and no other IPMs show any LEDs, the LA card has failed. If LED 3 is on, coaxial cable is not attached or IPM/ terminal control unit has failed.

Indicators have different meanings during bring-ups instead of functional operation, as described in the following sections. The IPM is initializing or failed self-diagnostic testing. LEDs 1, 2, and 3 display the error code. Replace the LC card.

LED 0 (top)

LED 1

The 3270 interface is disabled by the LMU, which only appears brief briefly during initialization.

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Table 3-3. 4430 LMU Card Cage Indicators (Continued) Figure 3-4 Reference Number 2 (continued) Indicator/Test Point Name Function IPM Cards LED 2 If strobing, the 3270 interface is busy; that is, message traffic is currently being sent and received. This is not an error condition and can be used to determine if the terminal control unit is trying to send a message to the LMU. It is illuminated 1 to 3 seconds. If on continuously, this is an error condition. Clear this by resetting the LC card (LMU does a retry) or by disconnecting and reconnecting the cable to the terminal control unit. If not on, message traffic is not currently passing over the 3270 interface. If traffic should be passing, the IPM is connected to the wrong terminal control unit port or the port is not properly attached logically to the HSC. LED 3 The IPM has been placed in the Not Ready mode following an IPM initialization. This is an error condition that often indicates cable or terminal control unit problems (see Green LED on page 3-18). Clear this condition by resetting the IPM (the LMU performs a retry operation) or by disconnecting and reconnecting the cable to the terminal control unit (coaxial cable) for this IPM. Note: The Level 02 LC PROMs show a Not Ready condition if connected to a 3174 terminal control unit. Bring-up indicator code A fault is indicated by the hexadecimal code of the four indicators condition. When illuminated, it represents a 1, with the top LED representing the MSB. A (1010) B (1011) C (1100) D (1101) E (1110) F (1111) The screen memory test progress failed. The LBUS test in progress failed. The FIFO test in progress failed. The 3270 timer test in progress failed. The timer test in progress failed. The previous test (D) or (E) failed.

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Table 3-3. 4430 LMU Card Cage Indicators (Continued) Figure 3-4 Reference Number 2 (continued) Indicator/Test Point Name Function IPM Cards Functional indicator codes 5 (0101) 4 (0100) 2 (0010) 1 (0001) 3 CPM card indicator LEDs The MSB indicator will be off; status is indicated in one or more of the other LEDs. At the end of bring-ups, the 3270 interface has not been enabled. 3270 disabled 3270 transfer is in progress. This is not a failure. 3270 interface is not ready or, if the green LED is off, the 3270 interface timed-out. These LEDs are driven by a byte-wide register during boot and IPL functions to display progress through the testing routines. The information present in the LEDs is redundant to the front panel display.

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Figure 3-4. LMU Card Cage Indicators

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Table 3-4. LCU Card Cage Indicators and Test Points Figure 3-5 Reference Indicator/Test Point Name Number LW (PLW) Card LED 1 2 Red LEDs LX Card LEDs Red LEDs Top (1) (2) (3) (4) (5) Bottom (6) LY Card LED 3 Green LED LP Card(s) LEDs 4 Red LEDs Top (1) TAK N (2) TAK E (3) PARITY (4) CRASH S (5) OVER C The encoder circuit detected noise The encoder circuit detected an error The LP card detected a parity error The Master or Standby PTP/ CEM crash switch was detected High current fault in power amplifier or motor lead shorted to ground One of the following was detected: parity, crash switches, overcurrent, current time-out (locked motor or excessively long-current commands) The DBR relay is closed The amplifier is enabled The servo time stamp is occurring every 12.5 ms A 5 V rest occurred A hardware reset occurred The REI reset is active An LX parity error occurred An REI parity error occurred A theta parity error occurred An LW parity error has occurred Function

Bottom (6) FAULT

Green LEDs

Top (1) EN DBR (2) EN AMP

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Table 3-4. LCU Card Cage Indicators and Test Points (Continued) Figure 3-5 Reference Indicator/Test Point Name Number LP Card Test Points 5 Top (1) DBRNO (2) CNTDN (3) CNTUP (4) MTRA (5) +ENDTR (6) TAKB (7) TAKA (8) +35 (9) CRAMP (10) MTRB (11) DIGITAL (12) DACCD (13) CURFB (14) BEMF (15) +13V (16) SLVSW (17) MSTSW (18) ERROR (19) -13V (20) PWMOS (21) DACOT (22) HIGH POWER GROUND (23) PWMA (24) PWMB Normally open contact of a DBR relay Count down pulses to counters Count up pulses to counters Output of the left side of the H bridge transistors Q6/Q8 Enables diagnostic encoder PAL Encoder Phase B Encoder Phase A Reads 0.1 times 35 V Absolute motor current value Output of the right side of H bridge transistors Q7/Q9 Digital ground test point Absolute value of DAC output Current feedback from amp (2.5 V/amp) back EMF across the motor +13.5 V +PTP/CEM Standby position limit switch +PTP/CEM Master position limit Output of error signal to PWM IC input -13.5 V Oscillator of 3637 IC Output of DAC (5 V) High power ground test pin A output of UC3637 MTR IC B output of UC3637 MTR IC Function

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Table 3-4. LCU Card Cage Indicators and Test Points (Continued) Figure 3-5 Reference Indicator/Test Point Name Number LP Card Test Points 5 (continued) (25) AMPCB (26) NFGTB (27) +CHB (28) +CHA (29) PFGTB (30) PGFTA (31) NFGTA (32) AMPCA Output of H bridge at CR58 anode Gate drive of N channel FET Q9 Driver output of U55, Pin 5 Driver output of U55, Pin 3 Gate drive of P channel FET Q7 Gate drive of P channel FET Q6 Gate drive of N channel FET Q8 Output of H bridge at CR56 anode Function

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Figure 3-5. LCU Card Cage Indicators (4411/9311/L5511)

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Table 3-5. REI Card Cage Indicators and Test Points Figure 3-6 Reference Indicator/Test Point Name Number 1 Top (1) DACCMD (2) CURAMP (3) C CEL (4) C DRV (5) DAC RIGHT (6) DAC LEFT (7) TAKA (8) TAKB (9) DGND (10) AGND 2 Red LEDs Top (1) -1MHz (2) TAK NOISE (3) TAK ERR (4) PAR ERR (5) CRASH STOP (6) TIME Function

LO Cards (2) Test Points RollL/Camera Lamps DAC command Amplified motor current The roll mechanism is against the clockwise stop The roll mechanism is against the counterclockwise stop DAC right voltage DAC left voltage Phase A of the roll mechanism encoder Phase B of the roll mechanism encoder Digital ground Analog ground The -1 M Hz clock has stopped The encoder decode PAL detected a noise condition The encoder decode PAL detected an error condition A parity error was detected on the data bus The roll mechanism has contacted the crash stop switch Current greater than 6A was requested for more than 3 seconds The roll DBR is energized The roll amplifier is enabled

LO Cards (2) LEDs Roll/Camera Lamps

Green LEDs

(7) ENDBR Bottom ENAMP (08)

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 3 Red LEDs Top (1) CURTIM Function

LN Cards (2) LEDs Reach/Finger The finger amplifier was energized too long (longer than 3 seconds) An overcurrent condition was detected in finger amplifier The finger amplifier is enabled -1 MHz has stopped The encoder decode PAL detected a noise condition The encoder decode PAL detected an error condition A parity error was detected on the data bus The reach mechanism has hit the reach stop Current greater than 6 A was requested for more than 3 seconds An overcurrent condition was detected in reach amplifier The reach DBR is enabled The reach amplifier is enabled

(2) OVERCUR Green LED Red LEDs (3) ENAMP-F (4) -1 MHz (5) TNOISE (6) TAKERR (7) PARITY (8) CRASH (9) TIME

(10) CUR Green LEDs (11) ENDBR (12) ENAMP

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 4 Top (1) FISTEP (2) FIDET (3) FISEAT (4) FICLOSE (5) FIOPEN (6) RESAFE (7) RECRASH (8) CURAMP (9) TACH-B (10) TACH-B (11) DACC (12) AGND (13) AGND (14) AGND (15) DGND (16) DGND (17) DGND (18) HPGND (19) HPGND (20) HPGND Function

LN Cards (2) Test Points Reach/Finger Step finger motor, one step per pulse A cartridge is present The fingers are fully seated around the cartridge The fingers are closed The fingers are opened The reach mechanism is positioned in the safe area The hand is at the reach mechanism stop Amplified motor current Phase B of the reach encoder Phase A of the reach encoder ADC Input 5: rectified DAC current command Analog ground Analog ground Analog ground Digital ground Digital ground Digital ground High power ground, +35 V ground return High power ground, +35 V ground return High power ground, +35 V ground return

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 5 Red LEDs Top (1) RESET OVERCUR Green LED Red LEDs (2) STS (3) -1 MHz (4) TNOISE (5) TAKER (6) PARITY (7) CRASH (8) TIME Function

LN Cards (2) Test Points Reach/Finger The card issued a remote reset An overcurrent condition was detected in finger amplifier Servo time stamp -1 MHz has stopped The encoder decode PAL has detected a noise condition The encoder decode PAL has detected an error condition A parity error was detected on the data bus The reach mechanism has hit the reach stop Current greater than 6 A was requested for more than 3 seconds An overcurrent condition was detected in reach amplifier The reach DBR is enabled The reach amplifier is enabled

(9) CUR Green LEDs (10) ENDBR Bottom ENAMP (11)

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 6 Top (1) (2) (3) Function

LU Card Test Points REI Turntable Spare Spare Allows a different clock to be injected into REI (unlabeled, card test usage) Disables the REI clock (unlabeled, card test usage) Analog ground High power ground

(4) (5) AGN (6) HPG (7) +12V (8) -12V (9) C CCW (10) C CW (11) AMPCTB (12) AMPCTA (13) CURAMP (14) ERRAMP

The turntable mechanism is against the CCW stop The turntable mechanism is against the CW stop Center of the H bridge on Channel B side of bridge AMPCTA Amplified motor current The amplified voltage difference between the DAC Current command and the actual motor current Gate signal to Q8; 0V is OFF, +10 V is ON Gate signal of Q6; 0V is OFF, +10 V is ON Gate signal of Q9; +35 V is OFF, 12V below +35V is ON Gate signal to Q7; +35 V is OFF, 12V below +35 V is ON 0 to 35 V signal used to turn on Q7 and Q8

(15) NFETGA (16) PFETGA (17) NFETGB (18) PFETGB (19) CH B

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 6 (continued) (20) CH A (21) AOUT (22) BOUT (23) PWM OSC (24) -STS (25) 6-BEMF Function

LU Card Test Points REI/Turntable 0 to 35 V signal used to turn on Q6 and Q9 0 to 5 V logic level used to turn on Q6 and Q9 0 to 5 V logic level used to turn on Q7 and Q8 23 KHz triangular reference waveform Servo time stamp ADC Input 6: amplified back EMF voltage was generated across the motor leads ADC Input 5: Rectified DAC current command ADC Input 4: Rectified and amplified motor current ADC Input 3: +35 V supply to the motor amplifier ADC Input 2: Motor Lead B ADC Input 1: normally open contact on DBR relay ADC Input 0: Motor Lead A DAC Current command The diagnostic path is enabled in the encoder PAL Count down pulse from encoder decode Count up pulse from encoder decode Phase B of the turntable encoder Phase A of the turntable encoder 1 MHz clock for synchronizing and gating

(26) 5-DACMD (27) 4- CURAMP (28) 3-+35V (29) 2-MTBR (30) 1-DBR NO (31) 0-MTRA (32) DAC CMD (33) +EN DTAK (34) CD (35) CU (36) +TAKB (37) +TAKA (38) 1 MHz

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 6 (continued) (39) +5V (40) DGND LV Card LEDs Z Servo 7 Red LEDs Top (1) TIMER (2) LOST 1MHZ (3) TNOISE A velocity error occurred 1 MHz is not functioning Noise occurred in the receiving tachs from the optical position encoder An error occurred in the receiving tachs from the optical position encoder A parity error occurred The theta arm stop assembly sensor was interrupted The current is above 6 A for more than 3 seconds Z amplifier overcurrent The Z DBR relay is energized The Z amplifier is enabled Digital ground Function

LU Card Test Points REI/Turntable

(4) TAKERR

(5) PARITY (6) CRASH (7) TIME (8) OVRCUR Green LEDs (10) ENDBR Bottom ENAMP (11)

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Table 3-5. REI Card Cage Indicators and Test Points (Continued) Figure 3-6 Reference Indicator/Test Point Name Number 8 (1) (2) (3)(8) (9) AGND (10) (11) TAKA (12) TAKB (13) C TOP (14) C BOT (15) HOME (16) CURAMP (17) DAC CMD (18) HPG (19) Bottom DGND (20) 9 Green LEDs Top (1) INPUT (2) OUTPUT Red LEDs (3) LOW VIN (4) HIGH TEMP (5) OVERVOLT Bottom UNDERVOLT (6) Function

LV Card Test Points Z Servo +12V -12V Spare Analog ground Spare Phase A of the Z encoder Phase B of the Z encoder The Z channel assembly is against the top stop The Z channel assembly is against the bottom stop The Z channel assembly positioned at the home sensor Amplified motor current DAC Current command High power ground Spare Digital ground

LS Card LEDs REI Regulator The voltage is present at the regulator input The voltage is present at the regulator output Regulator shutdown by inadequate input voltage A thermal shutdown occurred Regulator shutdown by 0V protection circuit Regulator shutdown by UV protection circuit

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Figure 3-6. REI Card Cage Indicators (4410)

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Table 3-6. LQ Card Indicators and Test Points Figure 3-7 Reference Indicator/Test Point Name Number 1 Red LEDs (1) CUR TIME (2) RESET (3) OVERCURRENT (4) PARITY (5) CRASH SW (6) POWER UNSAFE (7) OVERVOLTAGE 2 Green LEDs (1) DS1 Top (2) DS2 (3) DS3 Function

LQ Card LEDs Theta Servo The current command is greater than 10 A for 15 seconds LCU reset LQ card An amp or motor short was detected A parity error was detected The theta arm is in either crash switch The +5 V, +13.5 V, or -13.5 V supplies are below specification +100 VDC supply bus was pumped up to 145 VDC The amplifier is enabled The DBR relay coil is energized +100 V is present

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Table 3-6. LQ Card Indicators and Test Points (Continued) LQ Card Test Points Theta Servo 3 (1) (2) +DBR PWR (3) +13V (4) -13V (5) +5V (6) DAC CMD (7) I SENSE (8) TACH 0A (9) TACH 0B (10) DBR CL (11) +PWM EN (12) +CNT DWN (13) +CNT UP (14) +AMP DRIVE (15) -AMP DRIVE (16) HPG (17) +AMP OUT (18) -AMP OUT (19) +100V (20) +100V PUMP UP LPG - Low power ground +13.5V for DBR coil +13 V analog supply -13 V analog supply +5 V logic supply DAC output to PWM IC Load current Encoder Phase A Encoder Phase B DBR relay coil Enable bit to PWM Count down Count up PWM IC out for + command PWM IC out for - command High power ground + output for + command - output for - command +100 V supply +Shunt resistor across +100 V

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Figure 3-7. LQ Card Indicators and Test Points (4411)

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3270 Wrap

3270 Wrap
Refer to the Test F70 description in the Automated Cartridge System Diagnostic System Users Guide, PN 88555. This LMU diagnostic test verifies that the LC card 3270 interface hardware and firmware are functional. A coaxial jumper is placed between the IPM under test (Standby IPM is SIPM) and any other IPM in the same LMU (Master IPM is MIPM). The MIPM enters a mode where it emulates a 3274/3174, and then passes messages to and from the SIPM. The coaxial jumper can be attached at the LMU I/O tower between IPM ports, or at the terminal control unit (if both coaxial cables run to a single terminal control unit or two terminal control units in close proximity). Attaching the jumper at the terminal control unit verifies the coaxial cable, in addition to verifying the LC Card. Note that while running the 3270 wrap tests, the MIPM card edge LEDs have a slightly different meaning.

IPM/Terminal Control Unit Status Check


Refer to the Test F90 description in the Automated Cartridge System Diagnostic System Users Guide, PN 88555. This LMU diagnostic test presents to the user the information contained in the operation information area (OIA) line on the virtual screen in the IPM. The OIA appears as the bottom line on 3278 type terminals. Information contained there includes the Busy status of the IPM, Ready status, and 3270 type error codes (for example, 3XX-, 4XX-, 5XX-type codes). This information is useful in isolating the cause and type of intermittent 3270 faults.

Terminal Control Unit-Based Diagnostic Tests


Both IBM and McDATA have built in diagnostic and status functions that are available to the user. In the IBM terminal control unit it is called the Test mode, and in the McDATA terminal control unit it is called the LCP mode. These routines provide the user information about the device and host sides of the terminal control unit, number of given types of errors, configuration information, and internal health data. See the related documents listed in Appendix B, 4430 LMU Terminal Control Unit Interface, for more information on the use of these functions.

Channel Status Tracing


Channel traces taken during failed host-to-LMU communication attempts give valuable information as the Sense byte and Status byte that are returned to the host by the terminal control unit. See the appropriate related document listed in Appendix B, 4430 LMU Terminal Control Unit Interface, for a breakdown of the bit interpretation.

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LCU-CD Interface Problems


When problems are encountered in the LCU-to-CD interface, the LCU responds during IPL with a NC (non-communicating) message. Normally, the LCU responds with CM (communicating) for attached CD transports or drives that are installed. For two transport CDs, the two vacant transport positions are shown by the XX (non-existent) message.

LSMCD/Transport Configurations
An 4410 LSM can have one to four CD walls installed; a 9310 LSM can have one-to-four CD walls installed, one-to-four 9741/9741E walls installed, or a mixture of drive wall types. Wall Number 10, next to the access door, is always a CD/drive wall with hinges. Walls 1 through 9 may be a standard CD/drive (non-hinged) wall. Each CD may have two or four transports inside. Each 9741/ 9741E wall can have up to 20 9840/T9840/T9940 drives installed. A 9741E drive wall attached to an L5510 can hold up to 20 LTO drives or 9840/T9840/T9940.

Interconnecting Cables
Note: For 9840 tape drive installations, consult the 9840/T9840/T9940 Tape Drive Installation Manual, PN 95879, for information regarding interconnecting drive cabling. For LTO tape drive installations, consult the 9741E Drive Cabinet Installation and Maintenance Manual, PN 95969, for information regarding interconnecting drive cabling. Inside the LCU, a cable connects the motherboard connector J570 (CD 0 and 1) to LCU I/O panel connectors J623 (CD 0) and J624 (CD1). Another cable connects LCU motherboard connector J572 (CD 2 and 3) to LCU I/O panel J625 (CD 2) and J626 (CD 3). Four CD interface cables connect the LSM I/O panel connectors J623, J624, J625, or J626 to CD 0, 1, 2, or 3 connector J860 at the CD walls. Connectors on the CD interface cables are all labeled P62X at the LSM I/O panel end and J860 at the CD wall end. Inside the CD a cable with connector P160 connects the CD wall connector P860 to each transports I/O connector J47. P47 then connects to J61 of the transport motherboard connector. On CD Serial Number 879 and later, a separate cable (LCU interface adapter cable assembly) connects the CD wall connector J860 to each J160-0, -1, -2, and -3 transport connectors. The cables from J61 on the transport motherboards are routed out of the front of the transports where P160 can be connected to the LCU interface adapter cable assembly.

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CD Transport Installation
When a CD is installed, an LSM to CD I/O panel cable is routed from the LSM I/O panel connector, around the upper interior perimeter of the LSM, to the CD wall. The length of the cable depends on the physical positioning of the CD to the LSM. If a CD is not installed, a jumper plug must be installed in the unused LSM I/O panel connector. If a transport is not installed, a jumper must be installed in the CD to transport I/O panel cable P47 connector (below Serial Number 879) or J160 of the LCU interface adapter cable (Serial Number 879 and later). The LCU is shipped with jumper plugs installed in connectors J624, J625, and J626. These jumper plugs can be used to troubleshoot a portion of the LCU to CD/Transport Interface. The jumper plugs connect the transport out lines (driver) to the transport in lines (receiver) when a CD is not installed. The physical CD position in the LSM determines the LSM I/O panel connector (J623-J626) to use. Using the LSM access door as the reference, going clockwise, the first CD met is CD 0, the second CD 1, the third CD 2, and the fourth CD 3. If a new CD wall is installed between two existing CDs, the existing LSM to CD I/O panel cables that are installed clockwise from the new CD to the access door must be moved to the appropriate LSM I/O panel connector. For example, if there is a CD at Wall 1, 2, and 10 (the walls are numbered clockwise, the access door being Wall 11), and a new CD is installed at Wall 9, the cable in the LSM I/O panel CD 2 (J625) position must be moved to CD 3 (J626), and the new cable is installed in position CD 2 (J625). The physical position of the cartridge drive within a CD determines the transport connector in the cable to use. Viewed from inside the LSM, the upper connector is transport 0, the upper middle connector is Transport 1, and so on. If a CD does not have four transports installed, the unused transport connectors J160-X (P47-X on older units) are be secured to the corresponding transport frame and a jumper plug installed in the connector. If a new transport is installed, the jumper plug is removed, the transport cable is installed, and the transport cable connector is mated with connector J160 (P47 if before Serial Number 879). The terminating plug connects the transport in lines to the transport out lines.

Functional Operation
If a transport is not installed, the LCU receives an echo of its own command from the jumper instead of the normal response with ACK or NACK bits set. Now the transmission is retried. If an echo (not a response) is always received, the transport is in the not installed state.

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If an acknowledge is not received within 100 ms, the transmission is retried. If on all retries no response is seen, the transport is considered to be in the Not Available state. If an acknowledge is received, the transport is considered to be in the Available state and the status valid. If a negative acknowledge is received, or if a receive error occurs on a response, the LSM software retransmits the command. The LSM software does not track the installed or available status of the transports. Each command is handled individually and reports the current status of the transport.

Troubleshooting the LSM-CD/Transport Interface


During an IPL of the LSM, the LCU to CD/transport interface lines are polled and the status of each transport in each of the four available CD ports of LSM I/O panel is checked. This status can be displayed on a 392X Detached Diagnostic Device attached to the utility port of the LCU CSE service panel. Connect the 392X Detached Diagnostic Device to the utility port and press the IPL switch. Verify that each transport is either not present (jumper plug is installed) or communicating (transport installed). The displayed status remains on the 392X Detached Diagnostic Device screen for approximately a minute before it is scrolled off. The display appears as shown in Table 3-7. Table 3-7. LSM-to CD Transport Interface Unit Drive Status 0 0 CM 0 1 CM 0 2 CM 0 3 CM 1 0 CM 1 1 XX 1 2 NC 1 3 XX 2 0 XX 2 1 XX 2 2 XX 2 3 XX 3 0 XX 3 1 XX 3 2 XX 3 3 XX

Note: Status is displayed as CM (communicating), NC (not communicating), or XX (nonexistent). The preceding example shows a four-transport CD is installed at the CD 0 wall position (the first CD wall is clockwise from the access door). All transports are communicating through the interface. CD 1 at Wall 10 (hinged CD wall next to the access door) has two transports installed at transport Positions 0 and 2 with jumper plugs installed in the cable connectors for Positions 1 and 3. Transport 0 is communicating and Transport 2 is not communicating. CD 2 and 3 are not installed and a jumper plug is installed in the J624 and J625 connectors of the LCU upper I/O panel.

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If a transport is not communicating, there is a problem. The problem may exist in either the LCU to CD/transport interface cables/connectors, I/O connectors, or in the LCU or transport motherboards. Isolate the problem by using jumper plugs and the IPL procedure. Figure 3-8 on page 3-43 shows the interface for CD Serial Numbers below 879; Figure 3-9 on page 3-44 shows the interface for CD Serial Numbers 879 and later. The following procedure should isolate the problem in a timely manner: 1. Remove the LCU to CD I/O wall cable connector P62X of the affected CD transport from the LCU I/O panel. 2. Connect an LCU unused CD jumper plug, PN 4103322xx, to the I/O panel connector. 3. Press the IPL switch on the LCU. If the 392X Detached Diagnostic Device still displays NC for the transport in question, the problem is in the connector J62X, J75X, the cable between the two, or the LCU motherboard. If the response is XX, proceed with Step 4.

4. Disconnect the jumper plug and connect P62X back to connector J62X. Disconnect P160 (below Serial Number 879) or P860 from the CD wall connector J860 for the CD transport in question. Connect the jumper plug to J860 and press the IPL switch on the LCU. If the 392X Detached Diagnostic Device displays NC for the transport in question, the problem is in the LCU to CD wall cable or the CD wall connector. If the 392X Detached Diagnostic Device displays XX, proceed with Step 5.

5. Disconnect the jumper plug and connect the CD cable connector P160 or P860 back to the CD wall connector J860. 6. Disconnect the transport cable connector P47 (Serial Number below 879) from J47 or J160-2 from P160-2 (SN 879 and later). 7. Connect the transport jumper plug to the connector. The jumper plug part number for CDs below Serial Number 879 is 4029209xx. For CDs 879 and above the part number is 4029567xx. For two transport CDs, there are two of these jumper plugs attached to the cable connectors. If the CDs all have four transports, however, the jumper plugs to be used for this procedure must be requisitioned. The pin connections for all jumper plugs are shown in the notes on Figure 3-8 on page 3-43 and Figure 3-9 on page 3-44. If the 392X Detached Diagnostic Device displays XX, the problem is either in the transport cable connector J47, the transport cable to the

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motherboard on the transport, or the motherboard connector J61 (earlier serial numbers). For CD 879 and later, the problem lies in the transport cable or connector J160-X to P61 or the motherboard. If the 392X Detached Diagnostic Device displays NC for the transport, the problem is between J860 on the CD wall and the transport cable connector P47 (below Serial Number 879) or the LCU interface adapter cable (Serial Number 879 and above).

8. Return all jumpers to the original location after isolation of the problem. Figure 3-8. LCU-to-CD/Transport Interface (Serial Numbers Below 879)

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Figure 3-9. LCU-to-CD/Transport Interface (Serial Number 879 and Above)

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IPL Procedure

IPL Procedure
Use the following procedure to IPL the LSM: 1. Press the LMU operator panel power switch to ON. The LMU automatically IPLs. Note: If a fatal error during wake-up diagnostic testing causes the process to stop, press the LMU service panel IPL switch, which causes a hardware reset and initiates LMU power-on and IPL. If a non-fatal error occurs, press the LMU service panel RESET switch to attempt to continue the process.) 2. Press the LCU operator panel power switch to ON. The LCU automatically IPLs. Note: If a fatal error occurs, press the LCU service panel IPL switch. If a non-fatal error occurs, press the LCU service panel RESET switch.)

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Power System Maintenance

This chapter provides illustrations of the power supplies; a functional description of jacks, fuses, and circuit breakers; and block diagrams of the LMU and LCU power supplies and the interlock/emergency power-off (EPO) circuit. This chapter also provides the maintenance analysis procedures for the automated cartridge system (ACS) power system. These procedures address problems in the following power system components: Library management unit (LMU) power supplies Library control unit (LCU) power supplies Remote electronics regulator card (4410 only) Safety interlock/emergency power-off (EPO) system

LMU Power Supply


The 4430 LMU power supply information is supplied in the following sections.

General Information
The LMU power supply consists of three parts: The LMU AC box assembly The 12 V power supply assembly The +5 V power supply assembly

There are two PC cards: the LL card mounted in the LMU AC box assembly and the MR card mounted in the 12 V power supply assembly. The LMU power supply assembly and the 12 V power supply assembly are shown in Figure 4-1 on page 4-3. The controls and connectors are listed in Table 4-1 on page 4-4. The +5 V power supply assembly is shown in Figure 4-1. The terminals and connectors are listed in Table 4-2 on page 4-7. The LMU power supply operates with line voltages of 208, 220, and 240 VAC (176264 VAC), 50 and 60 Hz (4763 Hz). It provides the following voltages: 1. +5 V 2 percent for the LMU motherboard and the two floppy disk drives. 10.2 to 130.1 A, 75 mVpp ripple.

2. +12 V 5% for the LMU motherboard and the two floppy disk drives. 0 to 2.05 A, 150 mVpp ripple.

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3. -12 V 5 percent for the LMU motherboard. 0 to 0.5 A, 150 mVpp ripple.

4. 220 VAC for the three cooling fans in the LMU card cage. 5. 176264 VAC 50/60 Hz convenience outlet (J221). All outputs have overvoltage (OV) protection capability. The +5 V OV protection trips at 6.3 V 0.55 V and the 12 V trips at 14 V 1 V. After necessary repairs have been completed, the power must be recycled off and on again to restore operation. The total power supply is shutdown with an overvoltage condition of any output. None of the DC power supplies are equipped with external voltage (field adjustable) adjustments. Margining of the +5 V output is available to change the voltage by 3 to 5 percent either above or below the nominal value. Remote sensing capabilities are provided only in the +5 V output, within 250 mVDC of the nominal output voltage.

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Figure 4-1. LMU AC Box Assembly and 12 VDC Power Supply Assembly

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LMU Power Supply

Table 4-1. LMU AC Box Assembly and 12 VDC Supply Assembly Figure 4-1 Control/Indicator Reference Name Number 1 2 3 Connector J422 Circuit breaker CB402 LMU main circuit CB401 Function 176264 VAC, 50/60 Hz convenience outlet (same as input line voltage.) 5 A (for convenience outlet). 1 8A applies primary power to the LMU. It trips under EPO and overload conditions. The power is on when the switch is in the up position. 2.0 A S/B for 12 V power supply (MR card) 0.25 A S/B for LMU power control (LL card) EMI cover for AC input power Connects customer-provided AC to the LMU AC unit Connects the transformer for 240 VAC input using a voltage select plug Connects the transformer for 220 VAC input using a voltage select plug Connects the transformer for 208 VAC input using a voltage select plug Connects the 220 VAC power to the three cooling fans Connects 176264 VAC power to the +5 VDC supply DC test switch that checks for missed voltage Provides DC voltages to the operator panel Connects the AC control (LL) card to the LMU motherboard Connect the LL card to the Margin Hi and Lo circuits in the +5 V power supply. Connects the power supply DC voltages to the two floppy disk drives Indicates that +12 VDC is present (DS-10) Floppy Number 1 protection for the +5 VDC power supply (1.5 A S/B) Indicates that +5 VDC is present (DS-12) Floppy Number 2 protection for the +5 VDC power supply (1.5 A S/B)

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Fuse F401 Fuse F402 Power line access port Power line cable Connector J401 Connector J402 Connector J402 Connector J404 Connector J405 Switch SW1 Connector J412 Connector J413 Connector J414 Connector J423 +12 V LED Fuse F421 +5 V LED Fuse F422

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Table 4-1. LMU AC Box Assembly and 12 VDC Supply Assembly (Continued) Figure 4-1 Control/Indicator Reference Name Number 22 23 -12 V LED Connector J422 Function Indicates that -12 VDC is present (DS-11) Provides 12 VDC to the LMU motherboard and receives +5 V from the LMU motherboard for disk operation and voltage monitoring

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Figure 4-2. Older Model LMU +5 VDC Power Supply

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Table 4-2. Older Model LMU, +5 VDC Power Supply Figure 4-2 Control/Indicator Reference Name Number 1 2 Terminal board TB-1 Terminal board TB-2 Function Input voltage terminal board. Voltage input cable from J405 on the AC box. Factory selected for input voltage of 115 VAC or 230 VAC. Terminals 1 and 2, plus 3 and 4, are connected for 115 VAC input. Terminals 2 and 3 are connected for 230 VAC input. 3 4 5 6 Terminal GND Adjustment V-1 Connector J-1 +5 V output terminals Ground terminal for the ground lead from P405 on the AC box. Factory adjustment for the +5 VDC output; this is not a field adjustment. Connects to the LMU motherboard and AC power control (LL) card. +5 VDC output terminals, which provide +5 VDC to the motherboard.

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Figure 4-3. Newer Model LMU +5 VDC Power Supply

Table 4-3. Newer Model LMU +5 VDC Power Supply Figure 4-3 Control/Indicator Reference Name Number 1 Terminal board Function Input voltage terminal board. Voltage input cable from J405 on the AC box. Contains three terminals: the top is AC LO, the middle is AC HI (220 VAC return), and the bottom is chassis ground. Factory adjustment for the +5 VDC output; this is not a field adjustment. Connects to the LMU motherboard and AC power control card (LL card). +5 VDC output terminals, which provide +5 VDC to the motherboard and return.

2 3 4

Adjustment V ADJ Connector J1 + and - output terminals

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LMU Front Panel Interfaces


The power ON/OFF switch is located on the front panel. ON (up or in position) allows the DC power supplies, AC convenience outlet, and the AC fans to become active. When turned to the OFF position (down or out), a soft power-off signal is sent to the central processing module (CPM). The CPM completes operations in progress before commanding the power supply to shutdown. The power ON/OFF indicator is located in the LMU front panel within the ON/OFF power switch. It is activated when the ON/OFF switch is in the ON position and the LMU power is on. It is deactivated when the ON/OFF switch commands the power supply to shut down and the CPM allows the power to be off. The emergency power-off (EPO) circuit is activated with a red switch on the operator panel and is visible with all access doors either open or closed. When this switch is operated, LMU power is shut off immediately, overriding the regular unit power ON/OFF switch and any LMU processor power control. This is a local EPO only (there is no remote power off). When the EPO switch is activated, the AC power is removed as close to the incoming AC power line as possible. It trips a circuit breaker accessible only to the service representative; it cannot be reset from outside the LMU. The EPO switch is also used by software to force a power-off because of excessive temperature.

LMU Internal Controls


The main power circuit breaker CB401 (a double pole-breaker) is accessible only from inside the LMU. The convenience outlet circuit breaker CB402 (also a double pole-breaker) is accessible only from the inside the LMU.

Circuit Operation Description (LMU)


The LMU power supply consists of the AC box, the 12 V power supply, and the +5 V power supply (PS1). Figure 4-4 on page 4-11 is a block diagram of the LMU power supply and its loads. The LMU AC box contains the input filter, circuit breakers, power distribution, transformers, solid state relay, control card (LL), and the 176264 VAC, 50/60 Hz convenience outlet (output varies depending on the input voltage to the AC box). The 12 V supply is mounted on the side of the LMU AC control box. It can be removed easily from the LMU control box by unplugging two connectors and loosening four screws.

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The +5 V power supply is a separate package and can be independently removed from the LMU power supply.

LMU Control Box


The LMU power supply operates with either 208, 220, or 240 VAC, single phase, 50 or 60 Hz. LF-401 protects the power supply from conducted susceptibility and the line from conducted emissions. The power supply is protected from surge currents with VR-401. T-401 provides low voltage AC to the power control (LL) card. CB401 protects the LMU from overcurrent conditions and also may be activated by the EPO circuit. CB402 interrupts the voltage to the convenience outlet J221 should an overcurrent condition exist. T-402 provides low voltage AC to the 12 V power supply (MR card) and the 220 VAC for the three cooling fans. F-402 protects the LL card from overcurrent conditions. The line voltage select connectors are J401, J402, and J403. Selection is as follows: If the line voltage is 208 VAC, J403-1 is shorted to J403-2, T-402 receives the 208 VAC and steps up the voltage to 220 VAC for the fans and the 12 V power supply. If the line voltage is 220 VAC, J402-1 is shorted to J402-2, T-402 and the cooling fans receive the 220 VAC. If the line voltage is 240 VAC, J401-1 is shorted to J401-2, T-402 gets the 240 V and steps the voltage down to 220 VAC for the fans and the 12 V power supply.

T-402 always provides the operating line voltage for the 12 V power supply and the cooling fans at 220 VAC if the select plug is installed in the proper connection. CAUTION: Make sure that the shorted connector J401, J402, or J403 corresponds to the applied line voltage (240 VAC, 220 VAC, or 208 VAC respectively) to ensure the proper voltage is applied to the cooling fans.

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Figure 4-4. LMU Power Supply Block Diagram

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LCU Power Supply (Standard)

Control CardLL Card (LMU)


The LL card in the LMU contains the following: The +12 V and +5 V housekeeping power supplies. Power-up and power-down sequence controller. Margin control for the +5 V power supply. The card ID. EPO control. The voltage present interlock drive. When one of the DC voltages is not present, it is sensed by the LL card, and SSR-401 in the AC box interrupts the AC voltage. Switch S1 on the LL card allows the service representative to override this interrupt to determine the voltage that is missing. DS-10, DS11, and DS-12 on the MR card are illuminated if the respective voltages (+12 V, -12 V, +5 V) are present.

12 V Power Supply Assembly (MR Card)


The LMU 12 V power supply assembly (MR card) contains the 12 V power supplies and the voltage present interlock generator. The +12 V output is supplied to the motherboard and to the two floppy drives. The -12 V output is routed to the motherboard only. The 12 V power supplies have an overvoltage protection circuit. Also, the MR card has a sensor to determine the presence of +12 V, -12 V, and +5 V. If a voltage is missing, a signal is sent to the LL card, which turns the power off for the LMU.

+5 V Power Supply
The +5 V power supply is a 200 A switching power supply. The output is supplied to the motherboard and the two floppy drives. Margining of the +5 V, both high and low, increases or decreases the output value by 3 to 5 percent of the nominal value. Remote sensing of the output is provided within 250 mVDC from the nominal value. Overvoltage protection is provided to trigger if the output voltage increases to 6.3 V (0.55 V). The power supply provides 130.1 A maximum to the motherboard load. Each of the two floppy drives +5 V supply line is fused at 0.75 A.

LCU Power Supply (Standard)


The LCU power supply consists of the AC distribution box that includes the AC control (LK) card, the main transformer, the 4411 bulk DC power supply, and the power regulator (DX or MV) card. The MV card has replaced the DX card on LCUs manufactured after the release of the optional 80-cell CAP access door and on all LCUs with field conversions from the standard to the optional door.

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The MV card provides the additional power for the CAP solenoids and voltage for the display panel on the optional door. The LCU AC power supply provides AC voltage to the LCU main power transformer, LSM inside lights, Keep Alive voltage, and LCU fans. Electronics in the LCU and LSM run from the DC power supply powered from the LCU main power transformer. DC voltage is also provided for buses, isolated voltages for bias on the theta servo power amplifier, and LSM smoke detectors. The LK card is located in the AC power supply, the NG and NF cards are located in the bulk DC power supply, the DX (or MV) and LQ (4411) or PLQ (9311/L5511) cards are located in the LCU cabinet, and the LS card is located in the REI card cage on the 4410 (not used on the 9310/L5510). Figure 4-5 on page 4-14 and Table 4-5 on page 4-14 show and describe the LCU AC power supply switches, circuit breakers, fuses, and connectors. LCU/LSM power supply specifications are summarized as follows. Table 4-4. LCU Single Power Cord: AC Supply Specifications Input Voltages 200 VAC 10% 208 VAC +10% -15% 220 VAC +10% -15% 230 VAC 10% 240 VAC +10% -15% 4763 Hz 35 A at 176 V +40 V 20% 18 A continuous AC ripple: 1.5 V pp maximum +100 V 25% 3.3 A continuos 10 peak AC ripple: 5 V pp maximum

Input frequency Inrush current Output voltages: +40 V bus

+100 V bus

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Figure 4-5. LCU AC Power Supply (Standard)

Table 4-5. LCU AC Power Supply (Standard) Figure 4-5 Control/Indicator Reference Name Number 1 2 3 Connector J506 Connector J508 Connector J514 Function Provides the path to the operator panel power switch, indicator, and EPO switch from the AC control card. Provides the path to the motherboard for AC control logic signals. Provides AC voltage to the cooling fans, located below the motherboard.

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Table 4-5. LCU AC Power Supply (Standard) (Continued) Figure 4-5 Control/Indicator Reference Name Number 4 5 6 7 Connector J515 Connector J517 Connector J518 Connectors J510A,B,C Function Provides AC voltage to the DX (or MV) card cooling fans. Connects to the 12 VAC form the light transformer secondary to lower I/O tower on the LCU. Provides the path for interlock signals from LSM. Allow selection of the transformer taps to match the input AC voltage: J510A200/208 VAC J510B220 VAC J-10C230/240 VAC 8 9 10 11 Connector J522 Main power CB1 DCPS Input EPO Reset LCU transformer input jack Applies primary power to the LCU. Power is on when the switch is up; power is off when the switch is down. Input protection to the LCU DC power supply. Allows power to be applied after an EPO condition has been removed. See LSM Emergency Power-Off (EPO) on page 4-52 for the EPO reset procedure. 0.5A S/B protection for the keep-alive transformer 2A S/B protection for the cartridge storage subsystem lighting circuit.

12 13

Fuse F1 Fuse F2

Standard AC Distribution Box (LCU)


The LCU AC box provides AC power to the LCU main power transformer and the lights inside the LSM. All electronics in the LCU and LSM are operated from DC power supplies powered from the LCU main power transformer (see Figure 4-6 on page 4-16). The LCU keep alive supply (11.25 V, 0.50 A) and the LSM signs DC power supply (14 V, 1 A) also reside in the AC box. Input protection for the entire LCU AC box is provided by CB1 (250 V, 20 A, AP-30 delay). Input protection for the LCU main transformer is provided by CB2 (18 A, 250 V, AP-10 delay). CB2 is also a remote trip circuit breaker. When an EPO condition occurs, CB2 trips.

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Voltage tap change for the LCU main transformer, the keep alive transformer and the LSM lights transformer is achieved by changing the location of jumper plug P510 on the AC box front panel (J510A, J510B, J510C). AC current to the LCU main transformer is limited at turn on time by a soft start circuit made up of SSR1, SSR2 and R1 (5 , 90 W). The timing circuit for a soft start is located on the LK card. AC power to the LSM light transformer is controlled by Solid State Relay 3. SSR3 is controlled by the safety interlock switches on the LSM door and a delay/ pulsing circuit on the LK card. When the LSM door is fully open and locked open, SSR3 is turned on. When the LSM door is closed, SSR3 is pulsed for 30 seconds and the LSM lights flash on and off for 30 seconds before extinguishing. Pressing the EPO button will not affect this function. Figure 4-6. Standard LCU AC Box Functional Block Diagram

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AC Control (LK) Card


The LK card in the LCU is an analog printed circuit card that resides in the AC distribution box. It provides the following functions: Generation of the +11.25 V keep alive supply, +14 V supply for the LSM warning signs, and the +14 V EPO standby voltage from the 35 V bus. Provides the interface between the LCU operator panel and power ON/ OFF/EPO control hardware (solid state relays, remote trip circuit) in the AC box. Interfaces with logic so that logic can maintain an orderly shutdown on power-off. Provides the interface between the EPO remote trip circuit breaker and emergency power-off contacts (LSM internal EPO switch, crash stop limit switch, LSM smoke detectors and thermal switches, LCU motherboard thermal switch, and LCU operator panel EPO switch). Provides card level information to logic using an ID chip and interface bus. Provides the delay signals needed for the soft start circuit in the LCU AC box. Monitors the +35 V bus voltage and powers the LCU DC power supply off if an overvoltage condition occurs. Pulses the LSM ceiling light control solid-state relay to flash the LSM lights when the LSM door first closes.

LCU Transformer
The LCU main transformer primary winding is connected to the AC box through J522. The voltage applied to the primary winding is dependent on the AC input voltage from the customer supplied source and the location of the voltage selection plug P510 on the front of the AC box. The maximum input current is 16 A with 176 VAC input on the 200/208 VAC input tap (P510 in J510A). J514 and J515 are auto-transformed off the 220 VAC winding of the LCU main transformer for the LCU fans (220 VAC). J513 is auto-transformed by the 220 VAC winding of the LSM light transformer for the LCU AC box fan (220 VAC). The LCU AC box fan is only on when the LSM lights are on. The LSM lights (seven lights at 20 W at 12 VAC) connect to J517 that comes from the secondary of the LSM lights transformer in the AC box. This voltage is 13.0 V 0.4 VAC, 12 A at 220 V input.

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LCU Standard Bulk DC Power Supply


The LCU bulk DC power supply (Figure 4-8 on page 4-21) provides a +35 VDC bus voltage, a +100 VDC bus voltage, and a 20 VAC isolated voltage to provide bias on the theta servo power amplifier. It also provides +24 V for the LSM smoke detectors. Figure 4-7 on page 4-19 and Table 4-6 on page 4-20 show the controls, protective devices, and connectors of the 4411 LCU bulk DC power supply. The input power for the DC power supply comes from the LCU power transformer secondary AC voltage. The output voltages of the DC box follow: 35 V bus 100 V bus 24 V smoke detector supply 20 V AC RMS +35 V 20% (28.75 V44.75 V) +100 V 25% (75 V125 V) +24 V 10% 20 VAC +13% / -18%

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Figure 4-7. LCU Standard Bulk DC Power Supply

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LCU Power Supply (Standard)

Table 4-6. LCU Standard Bulk DC Power Supply Figure 4-7 Control/Indicator Reference Name Number 1 2 Connector J527 Connector J528 Function Connects +5 V and -13.5 V to the operator panel and +35 V to the motherboard for PTP/CEM 0 and 1 cards. Connects DX (or MV) card 5 V and 13.5 V outputs to the DC bulk supply and the +19.2 V output to the smoke detectors. Connects the +3 5 V output to the input of the power regulator DX (or MV) card. Connects +35 V to the LS card (4410) or PLS/PLF module (9310/L5510). Connects +35 V to remote electronic servo circuits. Provides AC and +100 V to the theta servo card. Protection for the following items: F1 F2 F3 F4 F5 F6 F7 8 9 Connector J523A Connector J523B 20 A, for 100 V bus to the theta card 2 A, for 20 VAC to the theta card 15 A, for +35 V to LCU PTP/CEM cards 20 A, for +35 V to REI servo 5 A, for_+35 V to LS (or PLS/PLF) card 20 A, for +35 V input to DX (or MV) card 2 A, for overvoltage protection

3 4 5 6 7

Connector J526 Connector J524 Connector J525 Connector J529 Fuse Block

Connects the LCU Transformer 30 and 80 VAC RMS to the 100 V bus rectifiers. Connects the LCU Transformer 20 VAC RMS to the 35 V bus rectifiers.

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Figure 4-8. LCU Standard Bulk DC Power Supply Block Diagram

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The +35 V bus to the LSM REI servos is controlled by Interlock Relay K1 and K2. K1, K2, and the NG card also provide DC soft start when the bus is interrupted. When -REI EN line is disconnected from DX/MV common by the LSM door interlock switches, K1 and K2 are de-energized, disconnecting the +35 V bus from J525. Input voltage to the bulk DC power supply comes from the LCU main transformer connectors J523A and J523B. Short circuit protection for J523A is provided by CB2 in the AC box. The smoke detector +24 V supply output on J528 may be shorted indefinitely without causing any damage to the supply. If a short circuit condition exists on the REI servo bus at power-on, protection circuits on the NG card prevents K1 from turning on and F4 might not blow.

LCU AC Dual Power Option


The LCU dual power option is available as a conversion bill. This option provides the LCU/LSM with the capability of handling two power sources, thereby offering power redundancy. The differences between the standard, single power configuration and the dual power option are listed in the section below.

Differences
Replacement of the single power configuration with the dual power cord option requires replacement of the: AC power supply The dual power feature contains: Two power cords Two switches that enable/disable power to the two AC circuit breakers (See Figure 4-9 on page 4-24).

DC power supply The dual power feature contains: Status LEDs Connection via cable to PLX logic card (required for ServiceTek)

LCU fan tray (DC fans replace the AC fans)

The linear transformer is disconnected and not used for the dual power option. Detailed differences between the standard and dual power option are outlined in Table 4-7 on page 4-23.

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Table 4-7. Dual Power OptionDifferences Items Replaced 1 Standard Configuration LCU AC Power Supply Dual Power Cord Configuration Replacement Dual Line Cord LCU AC Power Supply Function / Notes Standard Configuration: AC control via LK card. Generates 12 VAC lamp voltage. Generates 14 VDC sign voltage. Generates 12 VAC fan voltage. Single line cord. Dual Power Configuration: AC control via PLLK card. Generates 12 VDC lamp voltage. Generates 14 VDC sign voltage. Generates 12 VDC fan voltage. Generates 15V bias voltages for DC box (2). Dual line cord. 2 LCU DC Power Supply Dual Line Cord LCU DC Power Supply Standard Configuration: 100 VDC bulk regulator (1). 40 VDC bulk regulator (1). 20 VAC voltage for Theta Servo card (1). 24 V for smoke detectors (1). Dual Power Configuration: AC/400 V offline switcher, (2). 100 VDC offline switcher, (2). 100 V/40 V bulk regulator, (1). 20 VAC voltage for Theta Servo card (1). 24 V for smoke detectors (1). 3 4 5 6 7 8 LCU Logic Fan Tray (AC Fans) LCQ/DX Fan Tray (AC Fans) Linear Transformer DX (DC/DC PS) DC/DC PLS/PLF Card One line cord LCU Logic Fan Tray (DC Fans) LCQ/DX Fan Tray (DC Fans) Disconnected. DX (DC/DC PS) DC/DC on PLS/PLF card Two line cords Used in both configurations. Used in both configurations. Cooling fans for LCU logic. Cooling fans for Servo and DX cards.

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Similarities
While both the AC and DC supplies are replaced, the output connectors and the pin-out designations on the new supplies are identical with the standard supplies. On the dual power DC Supply, the output voltages (+40 V, +100 V) have a tighter tolerance and will fall within the original DC box output voltage specifications.

Dual Power OptionFunctional Block Diagram


The block diagram for the dual power option is shown below. Note: Please note that the customers AC input is connected/disconnected by SW0 and SW1. That is, the switches electrically precede the circuit breakers CB0 and CB1. Figure 4-9. Dual Power Option Block Diagram

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Dual Power OptionInternal Logic Cards


The logic cards (internal to the power supplies) associated with the dual power option are listed in the table below. These cards are not FRUs. Table 4-8. Dual Power Option Logic Cards Card Name Location Function AC to 15 V and Fan 12 V converter, two per card, multiple isolated 15 V outputs 15 V to Lamp 12 V converter. Sign 14 V regulator. Internal 11.25 V regulator. Interlock control. EPO control. Lamp flashing control. AC to 400 V converter, two per card. 400 V to 100 V converter, two per card. 100 V to 40 V converter, one per card. 20 VAC generator. 24 VDC regulator. 40 V interlock soft-start control.

PLLK Card Dual Power AC supply

PLAD Card

PLDD Card

Dual Power DC supply

Dual Power OptionAC Supply


The dual power option AC supply is shown in Figure 4-10 on page 4-26.

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Figure 4-10. LCU Dual Power Option: AC Power Supply

1 2

3 4

5 17

16 6 15 7 A 14 8 13

20

9 10 11

12

18

19

VIEW A
C29831

Table 4-9. LCU AC Power Option AC Supply Figure 4-5 Control/Indicator Reference Name Number 1 2 3 4 5 6 7 Connector J8 Connector J7 Connector J515 Connector J514 CB0 SW0 Lamp 0 Function +15 V to DC PLAD card and +12 V to fan. Line voltage to DC PLAD card. Provides +12 V to cooling fan. Provides +12 V to cooling fan. 20 A circuit breaker. 16 A 2-pole switch Indicates power available to supply 0.

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Table 4-9. LCU AC Power Option AC Supply (Continued) Figure 4-5 Control/Indicator Reference Name Number 8 9 10 11 CB1 SW1 Lamp 1 S1 EPO Reset Function 20 A circuit breaker. 16 A 2-pole switch Indicates power available to supply 0. Allows power to be applied after an EPO condition has been removed. See LSM Emergency Power-Off (EPO) on page 4-52 for the EPO reset procedure. To LCU motherboard. To LSM thermal switch, Door Open indicator, LSM EPO, +14V sign voltage. +12 V to LSM interior lights To LCU operator panel power indicator and EPO switch. Fan fuse Off = +15V good On = +15V overvoltage Input connector for line voltageused always. Input connector for line voltageused for second AC cord. Jumperfrom J-LF1. Used for single line cord connector operation only

12 13 14 15 16 17 18 19 20

J508 J518 J517 J506 F1 DC Fault LED J-LF0 J-LF1 P9

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LCU DC Power Supply (Dual Power Cord)


The LCU DC power supply is shown in Figure 4-10 on page 4-26. Figure 4-11. LCU DC Power Supply (Dual Power Option)

1 2

13 12 11
10

9 13 8 A
7

14

VIEW A

4 5 6 C29833

Table 4-10. LCU DC Power Supply (Dual Power Option) Figure 4-11 Reference Number 1 2 Control/ Indicator Name J526 J528 Function +40 V to the DX (or MV) card Connects the +40 V output of the DX (or MV) card to the operator panel and provides connection for the +24 V smoke alarm. Connects DX card output to the operator panel and provides +40 V (and return) to the PTP(s). +40 V to remote electronic servo circuits +40 V interlock protection to servo amplifiers

3 4 5

J527 J524 J525

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Table 4-10. LCU DC Power Supply (Dual Power Option) (Continued) Figure 4-11 Reference Number 6 7 Control/ Indicator Name J529 DC Status Function +100 V to theta power amplifier Status LEDs Green = Outputs within specifications Red = Outputs outside specifications Not lit = Supply disabled Green = AC source good Red = AC source bad Green = AC source good Red = AC source bad Fuses 10 11 12 13 14 F1 F2 F3 J523 J12 2 A, for 20 VAC to the theta card 2 A, for +40 V overvoltage sense circuit 5 A, for +40 V remote electronics interface Connection from the AC supply. +12 V and +15 V from AC supply

8 9

AC0 Status AC1 Status

Power Regulator (DX/MV) Card


The DX card is used solely in the 4411 LCU. The MV card is used in 4411 LCUs manufactured after July 1992 or 4411 LCUs converted to support the optional CAP access door. All 9311/L5511 LCUs have the MV card installed. The power regulator (DX or MV) card is a push-pull switching converter. A single stage and multiple winding transformer produce all outputs from the +35 VDC power supply. The feedback control loop is closed around the +5.1 V main channel at a tolerance of 2 percent. The other outputs are in fixed proportion to the +5 V, and have a tolerance of 10 percent. The output of the 4411 DX or MV card is routed to the motherboards on the LCU and LSM and the theta servo card (LQ) located in the LCU. Additional MV card outputs are routed to the MZ card on the optional 80-cell CAP access door. The output of the 9311/L5511 MV card is routed to the motherboard on the LCU, the PLS/PLF cards in the LSM, and the theta servo (PLQ) card located in the LCU. Additional MV card outputs are routed to the MZ card on the optional 80-cell CAP access door. Output voltages from the two cards are listed in Table 4-11 on page 4-30.

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Table 4-11. Output Voltages for the DX and MV Cards DX +13.5 V 13.5 V + 5.1 V 5.2 V (see Note 1) Notes: 1. The -5.2 V on the DX card is used when the card is installed in the 4480 Tape Cartridge Subsystem, but not used with the 4400 ACS. 2. The +12.3 V is used for the optional door display panel. MV +13.5 V 13.5 V + 5.1 V 5.2 V floating +12.3 V (see Note 2)

Overload Protection
This regulator uses a single set of power transistors to produce all the output voltages; therefore, overload protection is implemented by the total power from all outputs, rather than as a current limit for each individual output. When overload occurs, the output voltages are reduced. If overload persists, an undervoltage shutdown occurs to prevent overheating.

Overvoltage and Undervoltage


When any output exceeds its over or undervoltage trip points (20 percent above or below normal), the protection circuits disable all outputs. The protection circuit is reset by shutting off the LCUs DC circuit breaker until the LOW Vin LED is illuminated. Undervoltage protection is disabled for approximately one second after adequate input voltage is supplied. This allows the regulator to start before an undervoltage shutdown occurs.

Input Voltage Shutdown


The regulator shuts down if the input voltage falls below operational limits. The regulator remains off until the input voltage reaches approximately +30 V.

Test Points
Test points are provided for each output voltage, input voltage, and common. Figure 4-12 on page 4-32 and Figure 4-13 on page 4-34 show all test points and indicators that are located on the DX and MV cards respectively.

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Test points may be shorted to each other and to common without damage and without affecting regulator operation. Series resistance is 10 k at the input test point and 1 k at all others. The test points are on a six position pin header connector for the DX card. The MV card has an additional three pin header connector.

Status Indicators
The status indicators isolate major power system faults, where the lack of power makes it impossible to run the diagnostic routines. The lamps do not isolate the trouble to a single FRU, but show the general area and type of problem that exists. Normal conditions have green indicators; abnormal conditions have red indicators. The indicators for the DX and MV cards are shown in Figure 4-12 on page 4-32 and Figure 4-13 on page 4-34, respectively. They are described in Table 4-12 on page 4-33 and Table 4-13 on page 4-35. INPUT or 35 V This lamp is normally on, with brightness depending on the input voltage. If the lamp is off, there is no voltage at the regulator input.

OUTPUT or +5 V This lamp is normally on, indicating that voltage is present at the regulator card outputs. HI TEMP LOW VIN OVERVOLT UNDERVOLT This lamp is normally off. When it is on, thermal shutdown has occurred. This lamp is normally off. When it is on, the regulator is shut down because of inadequate input voltage. This lamp is normally off. When it is on, the regulator has been shut down by the overvoltage protection circuit. This lamp is normally off. When it is on, the regulator has been shut down by the undervoltage protection circuit.

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Figure 4-12. DX Card Test Points/Indicators

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Table 4-12. DX Card Indicators/Test Points Figure 4-1 2 Label Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 HI TEMP LOW VIN OVERVOLT UNDERVOLT OUTPUT INPUT +35 COM +5 -5 +13 -13 Color or Type Red Red Red Red Green Green Test point Test point Test point Test point Test point Test point

Function Thermal protector tripped +35 V source below operational limits Overvoltage protector tripped Undervoltage protector tripped Output voltage is active +35 V source is active +35 V source is active Common input/output return +5.10 V output (+5.00 V to +5.20 V) -5.20 V output (-4.68 V to -5.72 V) +13.5 V output (+12.00 V to +15.00 V) -13.5 V output (-12.00 V to -15.00 V)

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Figure 4-13. MV Card Test Points/Indicators

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Table 4-13. MV Card Indicators/Test Points Figure 4-1 2 Label Reference Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 HI TEMP LOW VIN OVERVOLT UNDERVOLT +5 V 35 V -13.5 +13.5 +12.3 V +5.1 V GND 1 +35 V -5.2 V GND F 3.23 V Color or Type Red Red Red Red Green Green TP1-1 TP1-2 TP1-3 TP1-4 TP1-5 TP1-6 TP 4-1 TP 4-2 TP 4-3

Function Thermal protector tripped +35 V source below operational limits Overvoltage protector tripped Undervoltage protector tripped Output voltage is active +35 V source is active -13.5 V output (-12.2 V to -14.8 V) +13.5 V output (+12.2 V to +14.8 V) +12.3 V output (+10.7 V to +13.9 V) +5.1 V output (+5.04 V to +5.16 V) Main ground reference +35 V input (+30.0 to +42.0 V) -5.2 V floating (-4.7 to -5.7 V) -5.2 V floating return 3.23 reference

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LCU AC Dual Power Option

Interface and Control


-MARGIN UP (INPUT) -MARGIN DN (INPUT) When this signal is asserted, the +5.1 V output is increased by 4 to 5 percent. The other outputs are increased by 3 to 6 percent. When this signal is asserted, the +5.1 V output is reduced by 4 to 5 percent. The other outputs are reduced by 3 to 6 percent. When both -MARGIN UP and -MARGIN DN are asserted at the same time, the effects cancel and output voltages are normal (but with the tolerances increased by 1 percent of the nominal voltage). This is asserted when the temperature is abnormally high. This occurs at a lower temperature than thermal shutdown to permit recording the warning in the error log and to allow completion of pending operations before the regulator is disabled. This output gives the state of the OVERVOLT status indicator. Note: Valid only if +5 V output is within usable limits. -UNDERVOLTAGE (OUTPUT) This output gives the state of the UNDERVOLT status indicator. Note: Valid only if +5 V output is within usable limits. -LOW INPUT (OUTPUT) This output gives the state of the LOW VIN status indicator. Note: Valid only if +5 V output is within usable limits. -POWER FAIL (OUTPUT) This line is asserted: When the input voltage drops below the LOW VIN threshold When an undervoltage condition is detected When an overvoltage condition is detected When a thermal shutdown occurs During start-up, until all outputs have been above their undervoltage thresholds for at least 50 ms. When POWER FAIL occurs, the regulator is enabled for 50 ms longer in every case except overvoltage shutdown. Outputs will hold up if input voltage and output loading allowance, as defined in the INPUT section.

-HIGH TEMP (OUTPUT)

-OVERVOLTAGE (OUTPUT)

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+ID DATA IN (INPUT) +ID DATA OUT (OUTPUT)

This signal transfers commands and data to the ID data EEPROM, in serial format. This signal transfers data out of the ID Data EEPROM, in serial format. Output data delay time is 2 s maximum from the positive clock edge. This output is enabled only when +REG ID SELECT is asserted. This line selects the regulator ID circuit and enables the +ID DATA OUT line driver. Data is transferred to and from the ID data EEPROM synchronous with this clock line, on rising edges of the clock pulse. The clock frequency may not exceed 250 kHz, and must have a duty cycle between 25 and 75 percent. This line is the ground reference for all interface and ID retrieval signals. This line is to be connected to the logic ground plane of the motherboard (which is also power supply ground). There is a small resistance between this line and the common power output to break the ground loop which would otherwise exist between the regulator and the logic motherboard. Voltage drop between INTERFACE GROUND and the common power supply output should not exceed 0.2 V peak.

+REG ID SELECT (INPUT) +ID SHIFT CLOCK (INPUT

INTERFACE GROUND

Power Regulator Connectors


Card connector pin assignments are shown in the following table. Input (J30DX and MV) +35 V input Pins 1, 2 Common input Pins 3, 4 Output (J31 and J32DX and MV)) -13.5 V output Pins 1, 2 +13.5 V output Pins 4, 5 -5.2 V output Pins 7, 8 (not connected on MV card) +5.1 V output Pins 10, 11, 13, 14 Low Level Signals (J33DX and MV) -Power Fail Pin 1 Interface ground Pin 2

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Spare (Input) -Margin Up -Margin Don +Reg ID Select +ID Shift Clock +ID Data In +ID Data Out -Low Input -Undervoltage -Overvoltage -High Temp Spare (Output) +5.2 V floating +5.1 V +5.1 V return GND +13.5 V -13.5 V +5.1 V

Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13 Pin 15 Pin 17 Pin 19 Pin 21 Pin 23 Pin 25 Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11

Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground Interface ground 5.2 V floating return +5.1 V +5.1 V return GND 1 +12.5 V and +13.5 V return (main GND 1) +12.3 V +5.1 V return (main GND 1)

Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14 Pin 16 Pin 18 Pin 20 Pin 22 Pin 24 Pin 26 Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12

CAP Power (J34MV only)

LSM Power Supply (4410 only)


The only power supply card located in the LSM is the remote electronics regulator (LS) card located in the REI card cage of the 4410 LSM. It is a DC-to-DC switching power converter, using a flyback circuit. The +35 VDC input is routed from the DC bulk supply located in the LCU. The +35 VDC is converted to a main output of +5 V and auxiliary outputs of 12 VDC. Two +24 VDC fan outputs are produced by linear regulators independent of the DC-to-DC converter. All inputs and outputs are safety extra low voltage (SELC) circuits. The LS card outputs are not isolated from the input. Protection circuits are provided for overload, low input voltage, high temperature, and output overvoltage or undervoltage. Indicator lamps are included for input and output presence and for the cause of regulator shutdown. An overvoltage or undervoltage condition on any output will cause all outputs to shut down. The regulator remains off until the protection circuit is reset.

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A non-volatile memory is provided for storage of card part number and other related tracking information.

Output Power (4410 LS Card)


The LS card regulates the +5 VDC, +12 VDC, and -12 VDC outputs with a continuous input operating range of 29.0 to 42.0 VDC. The output specifications are listed in Table 4-14 on page 4-40.

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Table 4-14. LS Card Outputs PARAMETER Tolerance (see Note 1) Untrimmed Trimmed (see Note 2) Load Current Minimum (see Note 3) Maximum (see Note 4) Ripple (pk-pk) (see Note 5) New/Recond (see Note 6) Wear-out limit (see Note 7) Overvoltage Minimum Maximum Undervoltage Minimum Maximum Notes: 1. With voltage margining inputs inactive 2. Only the main output (+5.0 V) is trimmed. Trimming compensates for manufacturing tolerances of components and is performed during manufacturing test. 3. If minimum load requirements are not met, outputs may be out of tolerance, which may cause the protection circuits to disable the regulator. 4. In addition to the individual output limits, the total power from all outputs shall not exceed 52 W. 5. For regulator-produced ripple only and specifically excludes load-generated noise. 6. This limit applies to any regulator installed as part of new or remanufactured equipment or as field replacement for a defective part. 7. This limit applies only as an end-of-life indicator for regulators already in service. The increase accounts for the normal aging of electrolytic filter capacitors. Nominal Voltages +12.0 V +1.0 / -0.6 N/A 0.80 A 1.50 A 100 mV 150 mV 14.0 15.25 9.2 10.0 -12.0 V 06 N/A 0.20 A 0.40 A 100 mV 150 mV 14.25 15.55 9.1 10.0 +5.0 V 0.15 0.6 3.50 A 6.00 A 65 mV 150 mV 5.95 6.4 3.95 4.2

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LSM Power Supply (4410 only)

Overload Protection
This regulator uses a single set of power transistors to produce the +5 V, +12 V and -12 V outputs. Therefore, overload protection is specified as the total power from all outputs, rather than as a current limit for each individual output. When overload occurs, the output voltages are reduced, causing an undervoltage shutdown. The regulator shuts down when any output is shorted to ground or to any other output without damaging the regulator. The regulator resumes operation after the short is removed and the undervoltage shutdown is reset. At 55 W total output power, the regulator does not shut down and the +5.0 V output remains above +4.75 V.

Overvoltage and Undervoltage Protection


When any output exceeds its over or undervoltage trip level, the protection circuits disable all outputs. The protection circuit is reset by momentarily reducing the input voltage to below the shutdown threshold. Undervoltage protection (only) is disabled for 0.25 to 0.80 seconds after adequate input voltage is applied. This allows the regulator to start before an undervoltage shutdown can occur.

Input Voltage Shutdown


The regulator is shut down if the input voltage (+35 V) falls to a range of +25.3 to +26.3 VDC. The regulator remains off until the input voltage increases by 1.75 to 3.65 VDC from the shutdown threshold.

Thermal Shutdown
Temperature of the LS card is monitored and a warning occurs at 50C (131F). If the temperature increases to 55C (131F), thermal shutdown of all LS card output voltages occur, except for power to the cooling fans. The High Temp indicator turns on, indicating the thermal shutdown.

Test Points
Test points are brought to the card connector for the input voltage, common, and the +5 V, +12 V, and -12 V outputs. Each test point has a current limiting series resistance. The +35 V test point uses 10 k and all others use 1 k .

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Status Indicators
The status indicators isolate major power system faults, where the lack of power makes it impossible to run the diagnostic routines. The lamps do not isolate the trouble to a single field replaceable unit (FRU) but do show what general type of problem exists. Normal conditions have green indicators; abnormal conditions have red indicators. Figure 4-14 on page 4-43 shows the LS card indicators and Table 4-15 on page 4-42 lists the meanings of the LS card LEDs. Input Output Low VIN High Temp This lamp is normally on, indicating presence of the +35 V supply. This lamp is normally on, indicating presence of +5 V (main output). This lamp is normally off. When it is on, the regulator is shutdown because of inadequate input voltage. This lamp is normally off. When it is on, thermal shutdown has occurred. Shutdown occurs if the temperature reaches 55C. All output voltages except the fan power are disabled. This lamp is normally off. When it is on, the regulator was shut down by the overvoltage protection circuit.

Overvolt

Table 4-15. LS Card Indicators Figure 4-14 Reference Number 1 2 3 4 5 6 Label INPUT OUTPUT LOW VIN HI TEMP OVERVOLT UNDERVOLT Color or Type Green Green Red Red Red Red Function +35 V source is active Output voltage is active +35 V source below operational limits Thermal protector tripped Overvoltage protector tripped Undervoltage protector tripped

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Figure 4-14. LS Card Indicators

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LSM Power Supply (4410 only)

Regulator (LS) Connector


All connections to the LS card are made through a 276 pin high density card connector to the REI motherboard. The pin assignments are shown in Table 4-16. Table 4-16. LS Card Pin Assignments Pin Number(s) A01A07 A08 A09A15 A16 A17A18 A19 A21 A20,A22 A23,A25 A27,A29 A31,A45 A24,A46 D01 D02 D08 D11 B01B07 B08 B09B15 B16 B17B18 B19 B21 B20,B22 B23,B25 B27,B29 B31,B35 B24,B46 E01 E02 E04 E08 E10 E11 C01C07 C08 C09C15 C16 C17C18 C19 C21 C20,C22 C23,C25 C27,C29 C31,C35 C24,C46 F01 F02 F07 F08 F11 +35 V (input) Not used (see Note 1) 35 V return Not used (see Note 1) Chassis ground (see Note 2) +24 V (Fan 1) +24 V (Fan 1) Fan return (even rows only) -12 V output (odd rows only) +12 V output (odd rows only) +5 V output (odd rows only) Common output (even rows only) +35 V test point High power ground test point -12 V test point +12 V test point +12 V test point Low power test point Common (see Note 3) -REG ID SELECT -ID DATA OUT -ID DATA IN -ID SHIFT CLOCK Common (see Note 3) -UNDERVOLTAGE -MARGIN UP -MARGIN DN Description

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Table 4-16. LS Card Pin Assignments (Continued) Pin Number(s) D12 D13 Notes: 1. These positions are not to be connected for any reason. They are guard space against short circuits on the input supply. 2. This connection is used for high frequency bypass capacitors. It is not the same as the common input/output. 3. Use these pins for logic signal reference. E12 E16 E22 E28 E34 E40 E46 F12 -HIGH TEMP -PWR FAIL -OVERVOLTAGE -LOW INPUT Common (see Note 3) Common (see Note 3) Common (see Note 3) Common (see Note 3) Common (see Note 3) Common (see Note 3) Description

Margining Voltages
When margining is activated, the +5.0 V output is either increased or decreased by 4 to 5 percent. The +12 V output is increased or decreased by 3 to 6 percent. The -12 V and the fan power outputs are not affected by margining the voltages up or down.

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LSM Interlock Circuitry

LSM Interlock Circuitry


The safety interlock and emergency power-off (EPO) system in the ACS serves two basic functions. It protects the operator or service personnel from bodily injury when entering the LSM and provides immediate power removal if smoke or fire is detected inside the LSM. If the latter occurs and the customer has an installed Halon extinguisher (optional) system in the LSM, the media is provided protection from fire and smoke damage. See Figure 4-15 on page 4-47 for the block diagram of the LSM interlock system.

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Figure 4-15. LSM Interlock/EPO System Block Diagram

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LSM Interlock Circuitry

LSM Entry
To prevent personal injury, three types of primary safety have been built into the system: Software interrupts (LAD open and door seated with HBO) +35 V disconnected from the REI servos using interlock relays in the DC box and REI door interlock switch Motors disconnected and shorted.

Service personnel can enter the LSM when the DO NOT ENTER sign is illuminated by using the following procedure. 1. Have the operator issue a MODIFY LSM x OFFLINE. 2. Open the LAD to expose the key lock. Note: If Step 1 is skipped, opening the LAD still activates a switch to automatically cause a software interrupt and stop the robot. This causes any mounts in progress to abend. 3. Obtain the LSM key ID plate from the appropriate customer representative and unlock the access door. Pull on the latch handle to open the door. At this point, several events occur: a. The door seated switch is deactivated by the locking pins.

b. Within 2 degrees of door rotation, voltage is removed from the REI servos and REI power is removed. Note: This switch can be overridden by the service representative to troubleshoot the remote electronics servos. It is located in the door frame header on the left-hand side accessible from the inside the LSM. A special tool is required to override the switch. When it is in the override position, +35 V is supplied to the REI servos and the entry sign changes to DO NOT ENTER. Voltages are present at the REI card cage area. c. All motors are shorted together and disconnected from their amplifiers.

d. The theta servo main interlock switch and the theta servo backup interlock switch activate. These are serial switches, and either of these switches is sufficient to disconnect the theta motor from the theta power amp. The main switch cannot be overridden or accessed by tool or by hand. It removes the theta enable signal from the theta power amplifier card, thereby removing the voltage path to the theta motor. Both switches remove voltage from the theta motor by disabling the DBR relay on the theta power amplifier card in the LCU.

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e. f.

The door HBO switch activates, which causes a software interrupt. The DO NOT ENTER sign illuminates.

4. Return the key lock to the locked position, remove the key, and close the LAD. This leaves the service personnel with the key in hand, changes the sign to SAFE TO ENTER, and jams the locking pins outward to prevent door closure (it holds the door open beyond 2 degrees and the switches cannot be reactivated). With key in hand, the service personnel may safely enter the library. If Step 4 is skipped (the key is left in the door lock and LAD is not closed), the library is still safe to enter. This, however, could lead to someone outside the library locking someone inside. If a person is locked inside, lights start flashing for 30 seconds while the software sets a 15-second delay. After 15 seconds, the robot slowly sweeps the area, in search of any obstruction (tool box, scope, human). If the robot is stopped momentarily, it shuts down, allowing the person to reach the door and exit. During this time, the person can find the door and open it by using the interior latch and/or activating the EPO switch. Either of these actions will stop any further power-up. (The inside door latch always allows someone to exit regardless of the exterior key position.) Also, during a normal initial power-up, the robot slowly sweeps the corridor in search of any obstruction. If the robot is stopped momentarily, it shuts down, allowing the person to reach the door and exit. The MG card provides the interface between the LSM door interlock switches, the LCU bulk servo power supply, and the LCU theta power amp. It also provides the interface between the LSM door interlock switches, the LSM warning signs, and the +14 V signs power supply. The MG card is located in the roof of the LSM near the door. The various states of the MG card are listed in Table 4-17 on page 4-50 and Table 4-18 on page 4-51. The pin assignments for the jacks listed in these tables are listed in Table 4-19 on page 4-53 through Table 4-23 on page 4-55. Three relays are located on the MG card. K1 is activated when the door is opened; K2 and K3 are activated when the door is closed. Table 4-17 on page 4-50 and Table 4-18 on page 4-51 indicate the switch contacts that should have continuity for a particular state. For example, with the door in State 1, S801 should have continuity between the NO (normal open) and COM (common) contacts.

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Table 4-17. MG Card Truth Table (Sheet 1 of 2)


STATES (see Note 1) 1 Switch/Pin LSM Door Closed, LAD Closed NO | COM NO | COM NO | COM NO | COM NO | COM +13.5 V Tied to DX/ MV COM 0 0 OFF 0 OFF 0 2 LSM Door Open, LAD Open (see Note 2) COM | NC COM | NC COM | NC COM | NC NO | COM 0 Open 0 13.5 ON 14 V 4 V OFF 0 3 LSM Door Open, LAD Closed COM | NC COM | NC COM | NC COM | NC COM | NC 0 Open Hi 9.716.7 13.5 OFF 0 ON 14 V 4 V 4 LSM Door in State 3, S801 in Override Mode NO | COM COM | NC COM | NC COM | NC NO | COM 0 Tied to DX/MV COM Hi 9.716.7 13.5 ON 14 V 4 V OFF 0 5 LSM Door in State 3, S801 in Override Mode NO | COM COM | NC COM | NC COM | NC COM | NC 0 Tied to DX/MV COM 0 13.5 ON 14 V 4 V OFF 0

S801 REI SVO interlock switch S802 theta SVO backup interlock switch S803 door status switch S804 theta SVO main interlock switch S805 LAD status switch Theta DBR DR J8011 -REI SVO EN J801-2 Door latched J801-7 Door open J801-8 DO NOT ENTER sign J803-1 SAFE TO ENTER sign J803-3 Notes: 1. 2.

LCU DC power supply OFF is the same as States 15, depending on the door position. All servos disabled by software through LAD status switch.
\

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Table 4-18. MG Card Truth Table (Sheet 2 of 2)


STATES (see Note 1) 1 Switch/Pin LSM Door Closed, LAD Closed NO | COM NO | COM NO | COM NO | COM NO | COM Tied to DX/ MV COM Tied to DX/ MV COM 0 0 OFF 0 OFF 0 Picked OFF +13.5 V 2 LSM Door Open, LAD Open (see Note 2) COM | NC COM | NC COM | NC COM | NC COM | NC Open Open 0 13.5 ON 14 V +4 V OFF 0 OFF Picked 0 3 LSM Door Open, LAD Closed COM | NC COM | NC COM | NC COM | NC NO | COM Open Open Hi 9.716.7 13.5 OFF 0 ON 14 V +4 V OFF Picked 0 4 LSM Door in State 3, S801 in Override Mode NO | COM COM | NC COM | NC COM | NC NO | COM Tied to DX/MV COM Tied to DX/ MV COM Hi 9.716.7 13.5 ON 14 V +4 V OFF 0 OFF OFF 0 5 LSM Door in State 3, S801 in Override Mode NO | COM COM | NC COM | NC COM | NC COM | NC Tied to DX/MV COM Tied to DX/MV COM 0 13.5 ON 14 V +4 V OFF 0 OFF OFF 0

S801 REI SVO interlock switch S802 theta SVO backup interlock switch S803 door status switch S804 theta SVO main interlock switch S805 LAD status switch Theta DBR DR J8012 -REI SVO EN J801-2 Door latched J801-8 Door open J801-8 DO NOT ENTER sign SAFE TO ENTER sign, J803-3 K-1 K-2 DBR DR J801-6 Notes: 1. 2.

LCU DC power supply OFF is the same as States 15, depending on the door position. All servos disabled by software through LAD status switch.

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LSM Interlock Circuitry

LSM Emergency Power-Off (EPO)


When either the EPO switch on the LCU or the one inside the access door is pressed, AC power to the LCU DC power supply is disconnected by two devices simultaneously: The remote trip circuit breaker The DC power supply ON/OFF solid state relay

Also, the DC power that controls these devices comes from two power supplies for redundancy. One is the keep alive supply; the other is derived from the +35 V bus. The two supplies are diode-ORed together. The pin locations for the interlocks, sign switches, and EPO interface are listed in Table 4-19 on page 4-53 through Table 4-23 on page 4-55. The various causes for an EPO are listed in Table 4-24 on page 4-56. Table 4-25 on page 4-57 lists the safety interlock truth table.

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Table 4-19. J-800 Interlock Switches Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 Description Normally open contact, S801 Common terminal, S801 Normally closed contact, S801 Normally open contact, S802 Common terminal, S802 Normally closed contact, S802 Not used Common terminal, S803 Normally closed contact, S803 Normally open contact, S804 Common terminal, S804 Not used

If the EPO was caused by the smoke detectors or the thermal switches in LSM, an LED on the LCU operator panel illuminates to show fire or smoke was sensed within the LSM. This LED remains illuminated until the EPO reset switch on the LCU AC box is pressed. In a Code A EPO, the LSM interior lights are also turned off through a solid state relay. After any EPO occurs, the service representative must: 1. Turn the operator panel ON/OFF switch to OFF. 2. Press the EPO reset switch on the LCU AC box. 3. Reset the remote trip circuit breaker (CB2) on the LCU AC box before normal operations may resume. After these three steps are complete and the cause of the EPO has been investigated and resolved, the LCU can be powered-on by turning the operator panel ON/OFF switch to ON. The service representative must activate the LCU operator panel EPO switch and the LSM door EPO switches to verify proper operation of the EPO circuit during scheduled maintenance (every six months).

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Table 4-20. J-801 LCU Interlock Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description +13 V pick voltage to theta DBR relay When tied to GND, enables 35 V to REI servos +13.5 V from DX/MV card (in LCU) DX/MV card common (in LCU) +13.5 V from LCU motherboard DBR +13.5 V through MG card K1 contacts +Door latched when LSM door open and LAD closed +12.8 V when LSM door open +11.25 V from LCU AC box, KA card Spare Spare Interface between LCU AC box, LK card, and LSM EPO devices +14 V 4 V (1 A) sign supply from LK card +14 V 1 A supply return line

Table 4-21. J-802 Warning Signs Switch Pin Number 1 2 3 4 5 6 Description Normally open contact, S805 Common terminal, S805 Normally closed contact, S805 Not used LSM door internal EPO Switch 1 LSM door internal EPO Switch 2

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Table 4-22. J-803 Warning Signs Pin Number 1 2 3 4 5 6 Description DO NOT ENTER 14 V sign drive signal Return 1 SAFE TO ENTER 14 V sign drive signal Return 2 Theta Enable 1,2Pin 5 tied to 6 at P803 Theta Enable 1,2Pin 7 tied to 8 at P803

Table 4-23. J-804 LSM EPO Interface Pin Number 1 2 3 4 5 6 7 8 9 Description Not used Not used Not used Not used LSM door internal EPO Switch 1 LSM door internal EPO Switch 2 Theta arm stop assembly, Switch 1 Theta arm stop assembly, Switch 2 Spare

Note: This table pertains to early level MG cards.

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LSM Interlock Circuitry

Table 4-24. EPO Causes EPO Source LSM smoke detectors A LSM thermal switches Condition causing the EPO Smoke detected inside LSM by either of two smoke detectors The temperature of the ambient air inside the LSM exceeds 41.7C 2C (107F 5F) sensed by both thermal switches The theta arm stop switch is closed by a runaway theta impact (see Note 1). The LSM door internal EPO switch is manually activated The EPO relay on the LX card is activated by the LCU microprocessor (see Note 2). +35 V bus voltage is greater than 47.5 V The EPO switch is manually activated 1. The LCU DC power supply through CB-2 and solid state Relay 2 2. The LSM lights through solid state Relay 3 LCU DC power supply through CB-2 and solid state relay (see Note 2) Components turned off LCU DC power supply through solid state Relay 2 LCU DC power supply through solid state Relay 2 LSM lights through solid state Relay 3 ON Smoke Indicator on LCU

Theta arm stop switch LSM door


EPO switch

LCU LX card EPO relay

OFF

Overvoltage sense circuit LCU operator panel EPO switch (red)

OFF

Notes: 1. Relates to earlier units only 2. A software-generated EPO (analog temperature sensors indicate a temperature in LCU or remote electronic exceeding 48.9C (2C) or 120F (5F).

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Table 4-25. LSM Safety Interlock Truth Table STATES1 1 2 LSM Door Open (Note 1), LAD Open (Note 2) Present Disabled Absent Disabled OFF ON OFF 3 LSM Door Open (Note 1), LAD Closed Present Disabled Absent Disabled ON OFF ON 4 Door in State 3, CSE Override Switch Activated Present Disabled Present Disabled ON ON OFF 5 6 LCU EPO Door in any Position, LCU DC Power Supply Off Absent Disabled Absent Disabled Same as State 15, per LSM door position

LSM Door Closed

Door Closing After CSE Override Present Disabled Present Disabled ON ON OFF

Theta card 100 V Theta motor REI SVO cards +35 V REI SVO motors LSM ceiling lights DO NOT ENTER sign SAFE TO ENTER sign Notes:

Present Enabled Present Enabled OFF (Note 4) OFF OFF

1. Greater than 2 degrees open. 2. When the LAD is open, servos are disabled by software, regardless of the status of the LSM door interlock switches. 3. Door greater than 2 degrees open, the latch rods are locked open. The door cannot be closed, and the theta servo is inactivated. 4. When the door is closed, the ceiling lamps will flash for 2030 seconds to warn the operator that the door has been closed.

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Lighting System

Lighting System
The LSM lighting system provides illumination for service and operator personnel when the LSM access door is open. There are two versions of the lighting system: In the 4410 and earlier versions of the 9310, the lights are controlled by the access door interlock switches. The seven interior lights are illuminated when the door opens and the LAD key is removed. If a lights bypass cable (PN 3084770xx) is installed, the interior lights remain on at all times (9310/L5510 only).

Sufficient illumination is provided by the lamps for human reading of the cartridge labels. When the access door is completely closed or when the main circuit breaker to the LCU AC box is first turned on (keep alive supply first comes on), the LSM lights pulse on and off for 30 seconds (20 percent), and then extinguish. In 9310/L5510 LSMs with a lights bypass cable, the ceiling lights stay on after they stop flashing. This delay is not affected by the LSM access door EPO switch.

Power Supply Fault Isolation


You must first determine the type of power system for the particular device.

LMU and 9310/L5510 Standard Power Supplies


Refer to the LMU and LCU power supply troubleshooting flow charts in Chapter 5, General Fault Isolation. The LSM does not have a separate power supply within it.

9310/L5510 Dual Line Cord Supply


There are six requirements for the Dual Line Cord supply: 1. The original AC supply must be replaced. 2. The original DC supply must be replaced. 3. The original AC fan boxes must be replaced with DC fan boxes. 4. The original LX card in the LCU card cage must be replaced with the LXP card. 5. A cable must be installed between the LXP card and the new DC supply. 6. The original transformer at the rear of the LCU must be disconnected. Refer to Table 5-1 on page 5-45 for the troubleshooting flow chart.

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4480 Cartridge Drive Power Supply

4480 Cartridge Drive Power Supply


There are no CD power supply components (circuit breakers, switches, fuses, or controls) accessible from inside the LSM. For information on the cartridge subsystem power supply controls, circuit breakers/fuses, connectors, and so on, refer to the appropriate cartridge subsystem maintenance or service manuals.

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4480 Cartridge Drive Power Supply

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General Fault Isolation

This chapter provides guidelines for fault isolation in the ACS. It contains fault isolation diagrams, explanation of the flow diagrams, and references to other sources of information on fault isolation. StorageTek service representatives (CSEs) should use the fault isolation flow diagram with corporate CSE Alert procedures.

Fault Isolation Procedure


A customer call is initiated either by the Central Support Services (CSS) or the customer services engineer (CSE). Following is a summary of the actions to take: 1. When the CSE is sent to the customer site by CSS. 2. When the CSE makes a routine call. If CSS initiated the call: 1. See Figure 5-1 on page 5-3 and Figure 5-2 on page 5-4. 2. Follow the flow diagram to the right of the box labeled Initiated by CSS. 3. Diagnose the problem according to Czars direction. 4. Replace a maximum of two FRUs as specified by CSS. 5. If the problem is resolved as a result, call CSS and complete the customer call. 6. If the problem is not resolved within two hours, collect and evaluate EREP, LOGREC, PM2 data, console sheets and/or M-Log (console message) information, and call a technical specialist. If the CSE initiated the call: 1. See Figure 5-1 on page 5-3 and Figure 5-2 on page 5-4. 2. Follow the flow diagram down from the box labeled Initiated by CSS. 3. Collect and evaluate EREP, LOGREC, PM2 data, console sheets and/or M-Log (console message) information.

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Fault Isolation Procedure

4. Evaluate the information to determine if a StorageTek machine is malfunctioning. (For system message information, refer to the message and codes manual available for the particular operating system being used.) If a StorageTek machine is not malfunctioning, call CSS to open a tracking incident and complete the service call. If a StorageTek machine is malfunctioning, analyze the information collected to determine the component of the ACS that is malfunctioning. If the malfunctioning unit is a 4480 Control Unit or Cartridge Drive/ Transport, refer to the 4480 Tape Subsystem Maintenance Manual to resolve the failure. If the malfunctioning unit is another type of control unit or drive, refer to the appropriate manual for the device.

5. Run diagnostic tests as directed by the Automated Cartridge System Diagnostic Systems Users Guide, PN 88555, to duplicate the problem and generate additional information (refer to the diagnostic error code dictionary for further information on the failure). If the diagnostic tests result in an indication of the problem area, schedule down time and replace a maximum of two FRUs to resolve the problem. If replacement of FRUs does not resolve the problem, call a technical specialist and CSS. If replacement of FRUs resolves the problem, complete the service call. If the diagnostic tests do not show a problem area, call a technical specialist and CSS.

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Figure 5-1. Fault Isolation Flow Diagram (Sheet 1 of 2)

CSE ENTRY

INITIATED BY CSS

YES

FOLLOW CSS DIRECTION

NO

COLLECT AND EVALUATE EREP/ LOGREC/PM2 DATA/ CONSOLE SHEETS/ M-LOG

REPLACE A MAXIMUM OF TWO FRUS

STORAGETEK MACHINE MALFUNCTION

YES

PROBLEM RESOLVED

YES

NO

NO

CALL CSS TO OPEN TRACKING INCIDENT

ANALYZE FAULT SYMPTOM CODE

COLLECT AND EVALUATE EREP/ LOGREC/PM2 DATA/ CONSOLE SHEETS/ M-LOG

CALL CSS TO CLOSE INCIDENT

CALL COMPLETE

CALL TECHNICAL SPECIALIST

CALL COMPLETE

TO SHEET 2 CSS = CUSTOMER SUPPORT SERVICES C28179

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Figure 5-2. Fault Isolation Flow Diagram (Sheet 2 of 2)

FROM SHEET 1 A

RUN DIAGNOSTICS

DIAGNOSTICS & FSC INDICATE PROBLEM AREA

YES

SCHEDULE DOWNTIME

NO

REPLACE A MAXIMUM OF TWO FRUs

PROBLEM RESOLVED

YES

CALL CSS TO CLOSE INCIDENT

NO

CALL TECHNICAL SPECIALIST & CSS

CALL COMPLETE

CSS = CUSTOMER SUPPORT SERVICES

C28180

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LMU Power Fault Isolation

LMU Power Fault Isolation


For isolating problems in the LMU power supply subsystem, use the troubleshooting flowchart in Figure 5-3 on page 5-6 through Figure 5-22 on page 5-25.

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LMU Power Fault Isolation

Figure 5-3. LMU Power Supply Troubleshooting Flowchart (Sheet 1 of 20)

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Figure 5-4. LMU Power Supply Troubleshooting Flowchart (Sheet 2 of 20)

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Figure 5-5. LMU Power Supply Troubleshooting Flowchart (Sheet 3 of 20)

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Figure 5-6. LMU Power Supply Troubleshooting Flowchart (Sheet 4 of 20)

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LMU Power Fault Isolation

Figure 5-7. LMU Power Supply Troubleshooting Flowchart (Sheet 5 of 20)

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Figure 5-8. LMU Power Supply Troubleshooting Flowchart (Sheet 6 of 20)

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Figure 5-9. LMU Power Supply Troubleshooting Flowchart (Sheet 7 of 20)

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Figure 5-10. LMU Power Supply Troubleshooting Flowchart (Sheet 8 of 20)

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Figure 5-11. LMU Power Supply Troubleshooting Flowchart (Sheet 9 of 20)

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Figure 5-12. LMU Power Supply Troubleshooting Flowchart (Sheet 10 of 20)

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LMU Power Fault Isolation

Figure 5-13. LMU Power Supply Troubleshooting Flowchart (Sheet 11 of 20)

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Figure 5-14. LMU Power Supply Troubleshooting Flowchart (Sheet 12 of 20)

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LMU Power Fault Isolation

Figure 5-15. LMU Power Supply Troubleshooting Flowchart (Sheet 13 of 20)

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Figure 5-16. LMU Power Supply Troubleshooting Flowchart (Sheet 14 of 20)

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LMU Power Fault Isolation

Figure 5-17. LMU Power Supply Troubleshooting Flowchart (Sheet 15 of 20)

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Figure 5-18. LMU Power Supply Troubleshooting Flowchart (Sheet 16 of 20)

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LMU Power Fault Isolation

Figure 5-19. LMU Power Supply Troubleshooting Flowchart (Sheet 17 of 20)

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Figure 5-20. LMU Power Supply Troubleshooting Flowchart (Sheet 18 of 20)

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LMU Power Fault Isolation

Figure 5-21. LMU Power Supply Troubleshooting Flowchart (Sheet 19 of 20)

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Figure 5-22. LMU Power Supply Troubleshooting Flowchart (Sheet 20 of 20)

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LCU/LSM Power Fault Isolation

LCU/LSM Power Fault Isolation


For isolating problems in the LCU/LSM power supply subsystem, use the troubleshooting flowcharts in Figure 5-23 on page 5-27 through Figure 5-40 on page 5-44. Sheet 1 (Figure 5-23) of the flowchart shows all of the cable connectors and the unit on which they are located.

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Figure 5-23. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 1 of 18)

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LCU/LSM Power Fault Isolation

Figure 5-24. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 2 of 18)

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Figure 5-25. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 3 of 18)

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Figure 5-26. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 4 of 18)

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Figure 5-27. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 5 of 18)

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Figure 5-28. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 6 of 18)

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Figure 5-29. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 7 of 18)

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Figure 5-30. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 8 of 18)

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Figure 5-31. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 9 of 18)

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Figure 5-32. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 10 of 18)

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Figure 5-33. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 11 of 18)

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Figure 5-34. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 12 of 18)

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Figure 5-35. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 13 of 18)

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Figure 5-36. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 14 of 18)

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Figure 5-37. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 15 of 18)

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Figure 5-38. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 16 of 18)

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Figure 5-39. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 17 of 18)

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Figure 5-40. LCU Power Supply (Standard) Troubleshooting Flowchart (Sheet 18 of 18)

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Table 5-1. LCU Power Supply (Dual Line Cord): Fault Isolation Table
AC Supply Indicator
AC IND-0 off AC IND-1 on

Fault

Condition
1. 2. 3. 4. 5. 1. 2. 3. 4. AC--0 Source < 150 V AC--0 plug pulled AC--0 wall CB off AC supply CB-0 tripped/open AC supply SW-0 open AC-1 Source < 150 V AC-1 plug pulled AC-1 wall CB off AC supply CB-1 tripped/open

DC Supply AC-0 LED

DC Supply AC-1 LED

DC Supply DC LED
1. 2. 3. 4.

Action Required
Check AC supply SW-0 Check AC supply CB-0 Check line cord -0 Check wall breaker for CB-0 Check AC source -0 Check AC supply SW-1 Check AC supply CS-1 Check line cord -1 Check wall breaker for CB-1 Check AC source -1

Red

Green

Green

5.
1. 2. 3. 4.

5. AC supply SW-1 open

AC IND-0 on AC IND-1 off

Green

Red

Green

5.

3 4

AC supply PLLK card 15 V_PRI_A bad AC supply PLLK card 15 V_PRI_B bad
1. 2. DC supply 400 V (0 or 1) out of spec. 100 V bus out of spec. 40 V bus out of spec. One 100 V converter failed

Both on Both on

Red Green

Green Red

Green Green

Replace AC supply Replace AC supply

5
3. 4.

Both on

Green

Green

Red

Replace DC supply

Loss of DC supply PLDD card PLDD_15V_SEC voltage from AC supply Loss of both AC sources to LCU Loss of LSM lamp voltage Loss of 12 V power to fans

Both on

Off

Off

Off

1. LCU off 2. Check AC-to-DC supply harnesses 3. Replace AC supply 4. Replace DC supply

7 8 9

Both off Both on Both on

Off Green Green

Off Green Green

Off Green Green

Check AC power (both sides) to LCU This fault is not detected Check F1 in AC supply. This fault is not detected

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Table 5-1. LCU Power Supply (Dual Line Cord): Fault Isolation Table (Continued)
AC Supply Indicator DC Supply AC-0 LED DC Supply AC-1 LED DC Supply DC LED

Fault

Condition Normal state (LCU on) Normal state (LCU off) After EPO from operator panel

Action Required

10 11 12

Both on Both on Both off

Green Green Red

Green Green Red

Green Off Off

None None

Note: After an AC loss, when power resumes, the DC LED may momentarily flash red during power up. The AC supply DC_FAULT LED will be red if a 15 V SEC OVP condition occurs. The AC supply should be replaced under this condition.

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Removal and Replacement Procedures

This chapter provides procedures for removal and replacement of components and subassemblies for and automated cartridge system (ACS), including those for: Models 4410/9310/L5510 Library Storage Module (LSM) 4411/9311/L5511 Library Control Unit (LCU) 4420/L5520 Pass-thru Port (PTP) 9320 Cartridge Exchange Mechanism (CEM) 4430 Library Management Unit (LMU)

On completion of removal/replacement actions, perform the appropriate equipment restoral procedure in Chapter 7, Equipment Restoral Procedures.

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LMU Components (4430)


Service the LMU from the back and front of the unit. To gain access for FRU removal and replacement or servicing the unit, unlatch the front and rear doors on the LMU. To open the latches, turn the screws counterclockwise approximately one-quarter turn, press on the end of the latch to open, and turn the latch one-quarter turn to position the latch lever away from the frame so that the door can be opened. The following sections describe the procedures that a service representative must follow when performing maintenance on a system with the Dual LMU (DLMU) configuration. Special procedures are required to ensure that the maintenance can be carried out on a non-functioning Standby LMU (SLMU) while the Master LMU (MLMU) is controlling the ACS.

Maintenance on a Non-Functioning SLMU


You can perform maintenance on a non-functioning SLMU in connected or disconnected (to the MLMU) state. However, a non-functioning SLMU must never be powered on in a partially connected state. That is, all local area network (LAN) and 3270 coaxial cables must be either connected in the DLMU configuration or none of them connected, before powering on or performing an IPL on the non-functioning SLMU.

Normal Maintenance/Troubleshooting
For cases where card swapping is to be performed on a failed LMU, the non-functioning SLMU can be powered up and down at will. Boot diagnostics can run in the SLMU. When powered down, cards can be swapped in the SLMU, as needed. Note: The DLMU motherboard contains the tap that is also located on the LB card, allowing the LB card to be replaced without affecting the performance of the other LMU. This must be done with all cables still connected to both LMUs. If the non-functioning SLMU is brought up with 3270 cables attached and with terminated LAN connections, then the non-functioning LMU will come up as a MLMU, even though the other LMU is already the MLMU. The host software component (HSC) recognizes a Master LMU on all 3270 connections, but half return not-communicating status for all LSMs in the ACS. If the LAN is then reconnected to the LMU, an error is sensed and an LMUB fatal might occur.

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Unusual Maintenance and Troubleshooting


In a case where special diagnostics must be performed on the non-functioning LMU, or where the non-functioning LMU must be swapped with a new LMU, the non-functioning SLMU must be disconnected from the DLMU configuration. To do this, power off the non-functioning SLMU. Disconnect all host I/F coaxial cables to the IPMs. Now disconnect the LAN 0 IN and OUT cables. Attach them to each other using a commonly available female-to-female adapter. (If LAN 0 has a terminator on IN or OUT, then connect that to the other cable.) Now, do the same for LAN 1. The non-functioning LMU is now disconnected from the DLMU and the MLMU is operating stand-alone. Any desired maintenance can be performed on the disconnected LMU. CAUTION: Possible system outage: Never connect a live LMU into an operating dual LMU system. Always power it off before connecting. Once it is fully connected to both LANs, only then should you apply power. To reconnect the LMU into the DLMU, or to install a new LMU into the DLMU, perform the disconnection procedure in reverse. Once reconnected, power on the LMU and it comes up as a SLMU.

Maintenance on A Live SLMU


To perform maintenance on the functioning SLMU, power it off (or perform an IPL). The MLMU notifies the HSC that the SLMU is down. Perform the maintenance as described previously for a non-functioning SLMU.

Maintenance on A MLMU
To perform maintenance on the functioning MLMU, it is desirable to perform an orderly forced S/O at the customers convenience using the HSC command, Force S/O. It is possible, however, to simply power off (or IPL) the MLMU. This causes the SLMU to become the new MLMU. Maintenance can then be performed on the now-SLMU as described previously. This latter technique is undesirable because the S/O transition is safest for the customer.

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Printed Circuit (LA, LB, LC/NN, and LI) Cards


See Figure 6-1 on page 6-5 and use the following procedures to remove and replace any printed circuit card in the LMU card cage.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling the logic cards. 2. Power down the LMU down by setting the operator panel power switch to OFF. 3. Remove the card cage cover to gain access to the logic cards. 4. Locate the defective card using the card label below the cards. 5. Pull both card ejectors away from the card to release the card from the motherboard connector pins. 6. Remove the card by holding it on the top and bottom and gently sliding it out of the card slot.

Replacement
1. Ensure that there is no damage to the card connector or connector pins on the motherboard. 2. Holding the card ejectors away from the card, gently slide the card into the correct slot, making sure it is properly seated in the card receptacle. CAUTION: Component damage: Do not force the card into the slot. If excessive force is required, remove the card and inspect for possible damage to the pins and/or receptacle. 3. Press the card ejectors toward the card, latching the card into the card cage. 4. Install the cover onto the card cage. 5. Apply power to the LMU by setting the operator panel power switch to ON. 6. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-1. Printed Circuit Card Locations (LMU)

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Motherboard Assembly (LJ Card)


See Figure 6-2 on page 6-8 and use the following procedures to remove and replace the LJ card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the power switch on the operator panel to OFF. 3. See the printed circuit card removal procedures but instead of removing the logic cards, leave them backed out about one-half way into the card slots. 4. Disconnect coaxial connectors P440, P441, P442, and P443 from the motherboard connectors J440, J441, J442, and J443, respectively. 5. Unsnap the plastic cover over the DC voltage terminals. 6. Disconnect P425, P426, P427, P428, P429, P430, P435, and P444 from their respective motherboard connectors (P436P439 if RS-423 cables are installed). 7. Disconnect the cables for the +5 VDC and ground cables by removing the four 1/4-20 common head screws and the flat and star washers from the motherboard. CAUTION: Component damage: Be sure to retrieve any washers inadvertently dropped when the four screws are removed before installing the new motherboard. 8. Remove the 14 screws that mount the motherboard to the card cage. 9. Support the motherboard and remove the four screws securing the motherboard to the LMU frame.

Replacement
1. Align the holes in the motherboard with the holes in the card cage. 2. Thread the 18 Torx screws into the motherboard to mount the motherboard to the card cage and LMU frame. Do not fully tighten the screws until after performing the next step. 3. Carefully insert the LI card (Slot B1) into the motherboard connector. 4. Remove the LC card from Slot E1 and carefully insert it into Slot W1. 5. Tighten all 18 screws to secure the motherboard in place. 6. Remove the LC card from Slot W1 and insert it back into LC card Slot E1. 7. Connect all cable connectors to their respective motherboard jacks.

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8. Connect the +5 V and ground cables to their respective locations using one 1/4-20 screw, flat washer, and star washer at each location. The two screws on the left-hand side have an additional +5 V and ground wires attached (see Figure 6-2 on page 6-8). 9. Install the plastic cover over the +5 V terminal strip. 10. Restore the LMU; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

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Figure 6-2. LMU Motherboard (LJ Card)

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AC Box (Power Supply Assembly)


See Figure 6-3 on page 6-10 and Figure 6-4 on page 6-11 and use the following procedures to remove and replace the AC box from the LMU.

Removal
1. Set the LMU operator panel power switch to OFF. 2. Set the AC input power supply circuit breaker (CB 401) to OFF. 3. Disable the customer-supplied AC power to the LMU. 4. Unplug the AC power cord from the customers power source. 5. Remove the AC power cable access cover plate from the front of the AC power supply. 6. Old version supply: Disconnect the LMU AC power cable (RS3720), and pull the cable and connector up through the access hole in the LMU power supply. New version supply: Remove the power cord: a. Unsnap the strain relief behind the power cord connector.

b. Disconnect the power cord connector from the power supply. c. Push the power cord connector and the cord down through the opening in the floor of the LMU.

7. Rotate the access cover plate 180 degrees, and install it onto the AC power supply. 8. Disconnect P404, P405, P412, P413, P414, P423, and P422 from J404, J405, J412, J413, J414, J423, and J422, respectively. 9. Loosen the two spring-loaded thumbscrews using a common-blade screwdriver. 10. Slide the AC power supply forward and remove the unit from the LMU. Avoid chafing the AC input power cable while the unit is being removed (old version).

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Figure 6-3. LMU AC Power Cord Connector

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Figure 6-4. 4430 LMU AC Power Supply

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Replacement
1. Install the voltage select plug into the same connector as the AC power supply that was removed. 2. Slide the AC power supply into place in the LMU chassis. The rear of the unit should engage the flange on the LMU frame. 3. Remove the AC power cable access cover plate from the front of the AC power supply. 4. Route the AC power cable connector and cable up through the opening in the floor of the LMU directly behind the power supply. 5. Plug the power cable connector into the connector on the front of the power supply. 6. Snap the strain relief into place. 7. Install the cable access cover plate onto the front of the AC power supply. CAUTION: Electromagnetic interference hazard: Make sure the cover plate covers the access hole completely to prevent electromagnetic interference (EMI) between the power cable and the LMU electronic circuitry. 8. Align the two holes in the front of the AC power supply with those in the frame, and then thread and tighten the two screws. 9. Connect P404, P405, P412, P413, P414, P423, and P422 to the J404, J405, J412, J413, J414, J423, and J422, respectively. 10. Connect the AC power cable RS3720 connector to the customer input power receptacle. 11. Enable the customer input AC power. 12. Set the LMU AC circuit breaker to ON. 13. Set the operator panel power switch to ON. 14. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Older Model DC Power Supply (PS1)


See Figure 6-5 on page 6-14 and use the following procedures to remove and replace the older model DC power supply assembly.

Removal
1. Set the operator panel power switch to OFF. 2. Set the AC input power supply circuit breaker (CB 401) to OFF. 3. Loosen the two alignment and hold down screws on the rear of the DC power supply approximately one turn. 4. Remove the two Torx screws in the front of the DC power supply. 5. Disconnect the +5 V and ground leads from the output terminals. 6. Disconnect the leads from TB1 (labeled 1 and 2) and the ground lead to the right of TB1. 7. Remove the connector in the center of the DC unit using a small common screwdriver to loosen the two screws holding it. 8. Remove the DC power supply by sliding it toward the front of the LMU.

Replacement
1. Install the DC power supply from the front of the LMU. Position the unit until the two slots in the rear of the unit align with the two screws in the LMU frame. 2. Align the holes in the front of the DC unit with the holes in the LMU frame. 3. Thread and tighten the two Torx screws in the front of the DC unit. 4. Tighten the two screws in the rear of the DC unit. 5. Connect the +5 V and ground leads to their respective terminals. 6. Connect the cable plug to the front center of the DC unit and tighten the two screws to secure it. 7. Connect the two leads (labeled 1 and 2) to the respective terminals on TB1 and the ground lead to the terminal to the right of TB1. 8. On TB2 (230 VAC input), connect Terminal 2 to Terminal 3. 9. Set the circuit breaker and to ON. 10. Set the operator panel power switch to ON. 11. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-5. Older Model LMU DC Power Supply

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Newer Model DC Power Supply (PS1)


See Figure 6-6 on page 6-16 and use the following procedures to remove and replace the newer model DC power supply assembly.

Removal
1. Set the operator panel power switch to OFF. 2. Set the AC input power supply circuit breaker (CB 401) to OFF. 3. Loosen the two alignment and hold down screws on the rear of the DC power supply approximately one turn. 4. Remove the two Torx screws in the front of the DC power supply. 5. Loosen the two connector screws and detach P1 from J1, pulling J1 from under the tie strap. 6. Disconnect the leads from the + and output terminals. 7. Pin the tabs on the terminal board, and remove the cover. Set the cover aside. 8. Disconnect the three leads from the terminal board. 9. Re-attach the cover on the terminal board. 10. Remove the DC power supply by sliding it toward the front of the LMU.

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Figure 6-6. Newer Model LMU DC Power Supply

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Replacement
1. Install the DC power supply from the front of the LMU. Position the unit until the two slots in the rear of the unit align with the two screws in the LMU frame. 2. Align the holes in the front of the DC unit with the holes in the LMU frame. 3. Insert one of the two Torx screws through the hole in the tie strap and thread, and tighten both Torx screws in the front of the DC unit. 4. Tighten the two screws in the rear of the DC unit. 5. Connect the + and leads to their respective terminals. 6. Pin the tabs on the terminal board, and remove the cover. 7. Set the cover aside. 8. Connect the three leads to the respective terminals on the terminal board. 9. Re-attach the cover on the terminal board. 10. Attach J1 to P1. 11. Set the circuit breaker to ON. 12. Set the operator panel power switch to ON. 13. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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LMU Components (4430)

12 VDC Power Supply


The 12 V power supply is mounted on the right-hand side of the AC power supply. See Figure 6-7 on page 6-19 and use the following procedures to remove and replace the assembly.

Removal
1. Set the operator panel power switch to OFF. 2. Set the AC input power supply circuit breaker (CB 401) to OFF. 3. Disconnect P422 and P423 from the front of the unit. 4. Remove the two nuts and split lock washers from the lower mounting studs. 5. Remove the two Torx screws from the top of the unit that attach it to the AC power supply. 6. Lift and tilt the 12 V power supply to the right to gain access to the two cables inside the unit. 7. Disconnect P424 from J424 located near the front of the unit. 8. Disconnect P421 from J421 at the AC power supply chassis. 9. Lift the power supply up, and remove it from the LMU.

Replacement
1. Position the 12 V power supply next to the AC power supply, and connect P421 and P422 to their respective connectors. 2. Place the power supply mounting holes over the two studs located at the bottom. 3. Align the holes in the power supply with those in the AC power supply chassis. 4. Thread and tighten the two Torx screws to secure the top of the unit to the AC power supply. 5. Install the two nuts and split washers on the studs to secure the unit at the bottom. 6. Connect P422 and P423 to their respective connectors on the front of the power supply. 7. Set the AC input power supply circuit breaker (CB 401) to ON. 8. Set the operator panel power switch to ON. 9. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-7. 12 Volt Power Supply

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Operator Panel (LD Card)


See Figure 6-8 on page 6-21 and use the following procedures to remove and replace the LMU operator panel (LD) card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the operator panel power switch to OFF. 3. Open the front door to the LMU. 4. Open the service panel on the right-hand side. 5. Set the AC input power supply circuit breaker (CB 401) to OFF. 6. Grasp the right-hand side of the operator panel door, and pull the door open to gain access to the LD card mounted on the inside the door. 7. Disconnect P470 and P471 from the J470 and J471 connectors, respectively, on the LD card. 8. Remove the seven Torx screws securing the LD card to the operator panel door.

Replacement
1. Align the holes in the LD card with the holes in the operator panel door. 2. Thread and tighten the seven screws to secure the LD card to the door. 3. Connect P470 and P471 to the J470 and J471 connectors, respectively. 4. Close and latch the operator panel door and service panel door. 5. Set the AC power supply circuit breaker to ON. 6. Set the operator panel power switch to ON. 7. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-8. LD Card

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IPL/Reset (MF Card)


The MF card is located behind the service panel and access to the card is from the rear of the LMU. See Figure 6-9 on page 6-23 and use the following procedures to remove and replace the MF card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the operator panel power switch to OFF. 3. Disconnect P472 and P474 from J472 and J474 on the MF card. 4. Remove the four nuts securing the MF card to the service panel.

Replacement
1. Install the card on the four studs on the rear of the service panel. 2. Connect P472 and P474 to J472 and J474, respectively. 3. Set the operator panel power switch to ON. 4. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-9. MF Card

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Cooling Fans
See Figure 6-10 on page 6-25 and use the following procedures to remove and replace any one of the three LMU card cage cooling fans.

Removal
1. Disconnect P469 from J469 on the rear of the fan cage assembly. 2. Remove the card cage logic card cover. 3. Loosen the spring-loaded thumbscrews on each side of the fan cage. 4. Slide the fan cage assembly out of the card cage enclosure. 5. Remove the filter from below the fans. 6. Remove the two Torx screws securing the defective fan to the fan cage. 7. Disconnect the fan power cable connector from the defective fan. 8. Remove the screw securing the ground lead from the fan.

Replacement
1. Connect the ground lead to the fan. 2. Connect the fan power cable connector to the fan. 3. Install the fan onto the fan cage using two Torx screws. 4. Install a clean fan filter beneath the fans. 5. Slide the fan cage into the card cage enclosure. 6. Align the fan cage with the card cage, thread, and tighten the spring-loaded thumbscrews on the side of the fan cage. 7. Connect P469 to J469 and visually check the fan for operation. 8. Install the card cage cover.

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Figure 6-10. LMU Fans

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Floppy Disk Drive


There are two floppy disk drives located behind the service panel. The upper floppy disk drive is numbered 1 and the lower is numbered 2. See Figure 6-11 on page 6-28 through Figure 6-13 on page 6-30 and use the following procedures to remove and replace either floppy disk drive. CAUTION: Configuration note: The replacement floppy disk drive must be configured properly for the Drive 1 or Drive 2 location. Figure 6-12 on page 6-29 and Figure 6-13 on page 6-30 show the proper placement of the jumper plugs and the terminator on the floppy disk drive motherboard. See Figure 6-12 for floppy disk drives supplied by Mitsubishi. See Figure 6-13 for floppy disk drives supplied by Panasonic.

Removal
1. Set the operator panel power switch to OFF. 2. Disconnect P1-0 and P2-0 if removing floppy disk Drive 1, or disconnect P1-1 and P2-1 if removing floppy disk Drive 2. 3. Remove the two screws from each side of the defective floppy disk drive that secure the drive to the housing. 4. Slide the floppy disk drive out of the housing from the front of the LMU.

Replacement
1. For Mitsubishi floppy disk drives, check the replacement floppy disk drive motherboard jumper plugs and terminator for proper configuration (see Figure 6-12 on page 6-29). The floppy disk drive is shipped with eight jumper plugs, a 2-pin connector, and a terminator. Drive 1 must have the terminator removed and a jumper plug installed in DS1 location. Drive 2 must have the terminator installed and the jumper plug moved from the DS1 to the DS2 location.

All of the other jumper plugs and the 2-pin connector locations are the same for both Drive 1 and Drive 2 configurations. For Panasonic floppy disk drives, check the replacement floppy disk drive motherboard jumper plugs for proper configuration (see Figure 6-13 on page 6-30). 2. Insert the floppy disk drive into the housing from the front of the LMU.

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CAUTION: Metric hardware: The hardware used to mount the Panasonic floppy disk drive is metric. Please use the hardware provided. 3. Align the holes in the housing and drive, and thread and tighten the four screws securing the drive. 4. Connect P1-0 and P2-0 if replacing Floppy Drive 1. 5. Connect P1-1 and P2-1 if replacing Floppy Drive 2. 6. Remove the head protective sheet from the replacement floppy disk drive and insert it into the defective floppy disk drive for shipment. 7. Set the operator panel power switch to ON. 8. Restore the LMU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-11. LMU Floppy Disk Drive

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Figure 6-12. Mitsubishi Floppy Disk Drive Configuration

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Figure 6-13. Panasonic Floppy Disk Drive Configuration

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Temperature Sensor (BY Card)


The three temperature sensor (BY) cards are located on top of the card cage and are replaceable from the rear of the LMU. Use the following procedures to remove and replace the BY card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Remove the cable connector from the defective sensor. 3. Note or mark the location of the BY card on the card cage. 4. Pull up on the BY card to unsnap the clip from the card cage rails.

Replacement
1. Snap the clip of the BY card into place at the same location as the one that was removed. 2. Connect the cable connector to the BY card.

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The LCU is serviceable from the front and left side as viewed from the front. Open the front door by turning the screw in each latch approximately one-quarter turn counterclockwise, press on the end of the latch to open, and turn the latch 90 degrees to clear the frame. The door will open and, if desired, can be removed by removing the pull pins in the hinges. Remove the side cover by loosening the screw at the top and bottom of the side panel. These screws are accessible from inside near the front of the unit. Once loosened, the side panel can be lifted and removed.

LCU Printed Circuit Cards


See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling the logic cards. Figure 6-14 on page 6-34 shows the location of the printed circuit cards in the card cage. Use the following procedures to remove and replace any of these cards.

Removal
1. Power down the LCU by setting the operator panel power switch to OFF. 2. Remove the card cage cover to gain access to the logic cards. 3. Locate the defective card using the card label below the cards. 4. Pull both card ejectors away from the card to release the card from the motherboard connector pins. CAUTION: Possible card/connector damage: For LXP cards, be sure to first remove the connector at J13 on the DC power supply. 5. Remove the card by holding it on the top and bottom and gently sliding it out of the card slot.

Replacement
Note: If the 4411 LZ card is being replaced, remove the paper between the battery contacts on the new card. 1. Ensure that there is no damage to the card connector or connector pins on the motherboard. 2. Holding the card ejectors away from the card, gently slide the card into the correct slot, making sure it is properly seated in the card receptacle. CAUTION: Component damage: Do not force the card into the slot. If excessive force is required, remove the card and inspect it for possible damage to the pins or receptacle.

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3. Press the card ejectors toward the card, latching the card into the card cage. Note: For LXP cards, insert the cable connector from the LXP card into J13 on the DC power supply. 4. Install the cover onto the card cage. 5. Apply power to the LCU by setting the operator panel power switch to ON. 6. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-14. LCU Printed Circuit Card Locations

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Motherboard Assembly (LT Card)


See Figure 6-15 on page 6-36 and use the following procedures to remove and replace the LCU motherboard.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the power switch on the operator panel to OFF. 3. Set the main AC breaker to OFF at the LCU. 4. Open the front door and remove the LCU side panel. 5. Unlatch the card cage by unscrewing the spring-loaded thumbscrews on the top and bottom brackets. 6. Slide the card cage fully forward. CAUTION: Component damage: Use care when moving the card cage to prevent damage to cables, connectors, and other hardware in the immediate area of the card cage. 7. Disconnect cable connectors P550, P553, P554, P555, P556, P566, P567, P568, P569, P570, P571, P572, P573, P574, P575, P580, P581, and P583. 8. Disconnect the coaxial BNC connectors P560, P561, P562, P563, P576, P577, P578, and P579 from the motherboard (P583 is door-type dependent and might not be present). 9. See the printed circuit card removal procedures; instead of removing the logic cards, leave them backed out about one-half way into the card slots. 10. Support the motherboard while removing the 15 Torx screws from the motherboard/card cage. 11. Leaving the cables attached to the cable supports, route the cables so that the motherboard can be removed, and carefully remove the motherboard out through the side of the LCU.

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Figure 6-15. LCU Motherboard (LT Card)

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Replacement
1. Position the motherboard onto the card cage, aligning holes in the motherboard and the card cage. 2. Thread the three screws at the top center of the motherboard to hold the motherboard into place. Leave the screws finger-tight. 3. Route the cables with cable supports into place and thread a Torx screw through the support and motherboard into the card cage. 4. Start the remaining screws into the motherboard but do not fully tighten. 5. Carefully insert the logic cards into the motherboard connectors. 6. Tighten all 15 screws to secure the motherboard in place. 7. Connect all cable connectors to their respective motherboard connectors (P583 is access-door-type dependent and might not be present). 8. Slide the card cage back into place in the LCU rails until the pins are aligned with the holes in the card cage. 9. Tighten the four spring-loaded thumbscrews to secure the card cage. 10. Install the logic card cover onto the front of the card cage. 11. Set the main AC breaker to ON. 12. Set the operator panel power switch to ON. 13. Restore the LCU; see Chapter 7, Equipment Restoral Procedures. 14. Loosen the two spring-loaded thumbscrews in the card mounting plate. 15. Carefully slide the unit out of the front of the LCU.

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Theta Box Assembly (LQ/PLQ Card)


The theta box assembly contains the LQ card for the 4411 or the PLQ for the 9311/L5511, card mounting and the cover. It is located on the right-hand side of the frame above the I/O tower. See Figure 6-16 on page 6-39 and use the following procedures to remove and replace the assembly.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the LCU operator panel power switch to OFF. CAUTION: Component damage: P595 contains the ground line and must be disconnected last to prevent possible damage to the card components. 3. Disconnect P590, P591, P592, P593, and P595 from their respective connectors. 4. Fold all cables and seat them between the frame members beside the LQ/PLQ card enclosure. CAUTION: Cable damage: Failure to seat the cables into this area causes undue wear because of chafing between the card mounting plate and cables.

Replacement
1. Slide the card enclosure into the rails. 2. Thread and tighten the two spring-loaded thumbscrews to secure the card to the LCU frame. CAUTION: Component damage: P595 contains the ground line and must be connected first to prevent possible damage to the card components. 3. Unfold the cables and connect P595, P590, P591, P592, and P593 to their respective card connectors. 4. Set the operator panel power switch to ON. 5. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-16. Theta Box Assembly (LQ/PLQ Card)

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Operator Assembly (LR Card)


See Figure 6-17 on page 6-41 and use the following procedures to remove and replace the LCU front panel printed circuit card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the operator panel power switch to OFF. 3. Open the front door of the LCU. 4. Set the AC power supply circuit breaker to OFF. 5. Open the operator panel door. 6. Disconnect P610, P611, and P612 from the LR card. 7. Remove the seven Torx screws from the printed circuit card that secure the card to the door.

Replacement
1. Align the LR card with the operator panel door and secure with the seven Torx screws. 2. Connect P610, P611, and P612 to their respective jacks on the printed circuit card. 3. Close the operator panel door. 4. Set the circuit breaker to ON. 5. Set the operator panel power to ON. 6. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-17. Operator Panel Assembly (LR Card)

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AC Power Supply Assembly (Standard)


See Figure 6-18 on page 6-44 and Figure 6-19 on page 6-45 and use the following procedures to remove and replace the LCU AC power supply.

Removal
1. Set the operator panel power switch to OFF. 2. Open the front door, pull the hinge pull pins, and remove the door. 3. Set the main AC circuit breaker to OFF. 4. Disable the customer AC power source to the LCU. 5. Disconnect the AC power cable connector from the customer power receptacle. 6. Remove the side panel from the LCU, if desired. 7. Disconnect P506, P508, P514, P515, P517, P518, and P522 from their respective connectors. 8. Remove the two 10-32 Torx screws from the front mounting flange of the AC power supply. 9. Old version supply: Slide the AC power supply out the front of the unit. Note: Be careful not to damage the power cable as you remove it from below the floor and the LCU frame. New version supply: Remove the AC power cable from the rear of the power supply. 10. Remove the cover plate from the rear of the power supply. 11. Unplug the power cord connector from the connector in the access hole in the rear of the power supply. 12. Push the power cord connector down through the hole in the floor of the LCU directly behind the power supply. 13. Replace the cover plate that you removed in Step 10. 14. Remove the voltage select plug, and install it into the same connector name on the replacement unit.

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Replacement
1. Slide the replacement power supply back until the tabs on the power supply engage the slots on the LCU frame. 2. Align the holes in the front mounting flange with the holes in the frame, thread, and tighten the two 10-32 Torx screws into the holes. 3. Connect P506, P508, P514, P515, P517, P518, and P522 to their respective connectors. 4. Connect the power cord to the power supply: a. Route the connector on the power supply end of the power cable up through the hole in the floor of the LCU directly behind the power supply.

b. Plug the power cord connector into the connector located in the access hole in the rear of the power supply. c. Replace the rear cover plate over the access hole in the rear of the power supply in such a way that the strain relief built into the plate is in place.

5. Enable the customer AC power source to the LCU. 6. Install the side panel and front door. 7. Set the main AC circuit breaker on the AC power supply to ON. 8. Set the operator panel power switch to ON. 9. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-18. Standard LCU AC Power Supply Connectors

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Figure 6-19. LCU AC Power Supply (Standard)

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AC Power Supply Assembly (Dual Power Cord)


See Figure 6-20 on page 6-47 and use the following procedures to remove and replace the LCU AC power supply.

Removal
1. Set the operator panel power switch to OFF. 2. Open the front door, pull the hinge pull pins, and remove the door. 3. Set both main AC circuit breakers to OFF. 4. Set both power switches to off. 5. Disconnect the AC power cable connectors from the customer power receptacles. 6. Remove the side panel from the LCU, if desired. 7. Disconnect P7, P8, P506, P508, P514, P515, P517, and P518 from their respective connectors. 8. Remove the two 10-32 Torx screws from the front mounting flange of the AC power supply. 9. Slide the AC supply out, pulling the power cords with it. 10. Remove the 10-32 Torx screw and AC box cord lock from underneath the power supply. 11. Remove the AC power cables from underneath the power supply. 12. Unplug the power cord connectors from their connectors. 13. Push the power cord connectors down through the hole in the floor of the LCU directly behind the power supply.

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Figure 6-20. LCU AC Power Supply (Dual Power Cord)

O PP A N E L P O W E R S W IT C H J9 JU M P E R P O W E R C O R D P O W E R C O R D

A C BO X C O R D L O C K

A C P O W E R S U P P L Y

S C R E W

VIEW A

J8 J7 J515 J514

C B0

S W 0

A J517 J518 C B1 J506 S W 1 S C R E W (2X ) J508

DETA IL A
C 29832

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Replacement
1. Slide the replacement power supply back until the tabs on the power supply engage the slots on the LCU frame. 2. Align the holes in the front mounting flange with the holes in the frame, thread, and tighten the two 10-32 Torx screws into the holes. 3. Connect P7, P8, P506, P508, P514, P515, P517, and P518 to their respective connectors. 4. Connect the power cords to the power supply: a. Route the connector on the power supply end of the power cable up through the hole in the floor of the LCU directly behind the power supply.

b. Insert the power plugs into the connectors located underneath the power supply. c. Replace the 10-32 Torx screw and AC box cord lock underneath the power supply.

5. Enable both customer AC power sources to the LCU. 6. Install the side panel and front door. 7. Set both switches on the front of the supply to ON. 8. Set both main AC circuit breakers on the AC power supply to ON. 9. Set the operator panel power switch to ON. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Bulk Regulator (DC Power Supply) AssemblyStandard


See Figure 6-21 on page 6-50 and use the following procedures to remove and replace the bulk regulator.

Removal
Set the operator panel power switch to OFF. 1. 2. Open and remove the front door from the LCU. 3. Set the AC power supply circuit breaker to OFF. 4. Remove the side panel from the LCU. 5. Disconnect P524, P525, P526, P527, P528, and P529 from the front of the DC power supply. 6. Disconnect P523A and P523B from the bottom of the DC power supply. 7. Remove the two Torx screws from the front flange of the DC power supply. 8. Slide the DC power supply out of the LCU frame.

Replacement
1. Slide the DC power supply into the frame of the LCU, positioning the flange on the power supply under the tab of the frame. This might require moving the rear of the power supply slightly from side to side to fully insert the unit and align the two front mounting holes. 2. When positioned, thread and tighten the two Torx screws to secure the power supply to the LCU frame. 3. Connect P523A and P523B to their respective connectors on the bottom of the power supply. 4. Connect P524 through P530 to their respective connectors on the front of the unit. 5. Install the side panel onto the LCU. 6. Set the AC power supply circuit breaker to ON. 7. Close the front door. 8. Set the operator panel power supply to ON. 9. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-21. LCU Bulk Regulator (DC Power Supply AssemblyStandard)

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DC Power Supply AssemblyDual Power Option


See Figure 6-22 on page 6-52 and use the following procedures to remove and replace the DC power supply.

Removal
1. Set the operator panel power switch to OFF. 2. Open and remove the front door from the LCU. 3. Set both AC power supply circuit breakers to OFF. 4. Remove the side panel from the LCU. 5. Disconnect P13, P524, P525, P526, P527, P528, and P529 from the front of the DC power supply. 6. Disconnect P523 and P12 from the bottom of the DC power supply. 7. Remove the two Torx screws from the front flange of the DC power supply. 8. Slide the DC power supply out of the LCU frame.

Replacement
1. Slide the DC power supply into the frame of the LCU, positioning the flange on the power supply under the tab of the frame. This might require moving the rear of the power supply slightly from side to side to fully insert the unit and align the two front mounting holes. 2. When positioned, thread and tighten the two Torx screws to secure the power supply to the LCU frame. 3. Connect P12 and P523 to their respective connectors on the bottom of the power supply. 4. Connect P13 and P524 through P530 to their respective connectors on the front of the unit. 5. Install the side panel onto the LCU. 6. Set both switches on the front of the AC supply to ON. 7. Set both main AC circuit breakers on the AC power supply to ON. 8. Close the front door. 9. Set the operator panel power supply to ON. 10. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Figure 6-22. DC Power Supply AssemblyDual Power Option

OP PANEL POWER SWITCH

DC POWER SUPPLY A J12 J523

VIEW A
AC CIRCUIT BREAKERS

J526 J528

J527

J13

J524 J525 J529

DETAIL A
SCREW (2X) C29834

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Power Transformer (Single AC Source Power Supply)


Note: The power transformer is only used with the single source AC power supply. For the dual power option AC power supplies, it remains in place but is not functional. The LCU power transformer can be replaced without removing the LCU from the LSM if the AC power supply and the LQ/DX (or MV) cards fan cage assembly are both removed. See Figure 6-23 on page 6-54 and use the following procedures to remove and replace the transformer.

Removal
1. Set the operator panel power switch to OFF. 2. Open and remove the LCU front door. 3. Set the AC power supply circuit breaker to OFF. 4. Remove the LCU side panel. 5. See the removal procedure for the AC power supply (page 6-42), and perform those steps. 6. See the removal procedure for the LQ/DX (or MV) cards fan cage (page 6-59), and perform those steps. 7. Disconnect P522 from J522 on the AC power supply and P523A and P523B from J523A and J523B on the DC power supply. 8. Remove the three allen-head bolts located on the right front, left front, and left rear of the transformer. 9. Grasp the transformer, and turn the assembly clockwise to obtain access to the allen-head bolt on the right rear of the transformer. 10. Remove the right rear bolt and the transformer.

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Figure 6-23. LCU Main Power Transformer (Standard AC Power Supply)

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Replacement
1. Position the transformer inside the frame, and align the right rear mounting hole with the respective mounting hole in the frame. Rotate the transformer clockwise to gain access to thread the bolt. 2. Thread and tighten the right rear bolt. 3. Grasp the transformer and rotate it counterclockwise until the other three holes are aligned. 4. Thread and tighten the bolts securing the transformer to the frame. 5. Connect P522, P523A, and P523B to their respective connectors located on the AC and DC power supplies. 6. See the replacement procedure for the LQ/DX (or MV) cards fan cage assembly (page 6-74), and perform those steps. 7. See the replacement procedure for the AC power supply (page 6-43), and perform those steps. 8. Install the LCU side panel. 9. Set the AC power supply circuit breaker to ON. 10. Install and close the LCU front door. 11. Set the operator panel power switch to ON. 12. Restore the LCU; see Chapter 7, Equipment Restoral Procedures.

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Temperature Sensor (BY Card, Card Cage)


To remove the temperature sensor from the card cage, first remove the fan cage to gain access to the bottom of the card cage. Use the following procedures to remove and replace the temperature sensor.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the operator panel power switch to OFF. 3. Open the LCU front door. 4. Disconnect P600 from the fan cage. 5. Remove the card cage front cover. 6. Unscrew the two spring-loaded thumbscrews securing the fan cage, and remove the fan cage from under the card cage. 7. Unsnap the BY card mounting clip from the bottom of the card cage. Disconnect P330-C from the BY sensor.

Replacement
1. Connect P330-C to the BY sensor. 2. Snap the BY sensor mounting clip to the card slot rails in the same location as the one removed. 3. Install the fan cage below the card cage, ensuring that the fan cage is positioned on top, and not under, the guides for the fan cage. 4. Tighten the two thumbscrews securing the fan cage to the card cage. 5. Connect P600 to J600. 6. Install the card cage front cover. 7. Close the LCU front door. 8. Set the operator panel power switch to ON. 9. Restore the LCU; see Library Control Unit Restoral in Chapter 7, Equipment Restoral Procedures.

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LCU Card Cage Fan


See Figure 6-24 on page 6-58 and use the following procedures to remove and replace the cooling fan in the fan cage located below the card cage assembly.

Removal
1. Power down the LCU by setting the operator panel power switch to OFF. 2. Open the front door on the LCU. 3. Disconnect P600 from J600 on the fan cage. 4. Remove the card cage front cover. 5. Unscrew the two spring-loaded thumbscrews securing the fan cage to the card cage. 6. Slide the fan cage out from under the card cage. 7. Remove the filter from the fan cage. 8. Remove the power connector and ground lead from the defective fan. 9. Remove the two screws and nuts securing the fan to the fan cage.

Replacement
1. Align the fan with the fan cage and secure the fan with two screws and nuts. 2. Connect the ground wire and power cable connector to the fan. 3. Insert a clean filter in the tray beneath the fans. 4. Slide the fan cage into the card cage and secure with the two spring-loaded thumbscrews. Note: Ensure that the fan cage is inserted on top of the tabs extending from the card cage that support the fan cage. If the fan cage is inserted below these tabs, the fan cage will be loose inside the enclosure. 5. Apply power to the LCU by setting the operator panel power switch to ON.

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Figure 6-24. LCU Card Cage Fans

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LQ/PLQ and DX/MV Card Fan)


See Figure 6-25 on page 6-60 and use the following procedures to remove and replace a fan in the LQ (or PLQ) and DX (or MV) fan cage. Note: The dual power cord configuration changes the LQ (or PLQ) and DX (or MV) fans to +12 VDC fans.

Removal
1. Power down the LCU by setting the operator panel power switch to OFF. 2. Open the LCU front door. 3. Disconnect P515 (and P514 for the dual power cord supply only) from the AC power supply. 4. Unscrew the two spring-loaded thumbscrews that secure the fan cage to the frame. 5. Slide the fan cage out from below the LQ/PLQ card enclosure. 6. Disconnect the defective fan power cable connector, and remove the ground lead from the fan. 7. Remove the four Torx screws that secure the fingerguard to the fan. 8. Remove the four Torx screws that secure the fan to the fan cage.

Replacement
1. Align the fan to the fan cage and secure the fan with four Torx screws. 2. Attach the fingerguard to the fan using four Torx screws. 3. Connect the fan power cable connector and the ground lead to the fan. 4. Slide the fan cage into place below the LQ/PLQ card enclosure, and secure to the frame with the two spring-loaded thumbscrews. 5. Connect P515 to J515 (and P514 to J514 on the dual power cord supply only) on the AC power supply. 6. Apply power to the LCU by setting the operator panel power switch to ON.

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Figure 6-25. LQ/PLQ and DX/MV Cooling Fans

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IPL RESET (NB Card)


See Figure 6-26 on page 6-62 and use the following procedures to remove and replace the NB card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the operator panel power switch to OFF. 3. Open the LCU front door and remove the side panel. 4. Disconnect P615, P616, and P617 from their respective connectors on the NB card. 5. Remove the top 10-32 Torx screw from the bracket holding the NB card. 6. Turn the bracket from vertical to horizontal position. 7. Remove the four #6 Torx screws that secure the NB card to the bracket.

Replacement
1. Position and secure the NB card to the bracket with four #6 Torx screws. 2. Turn the bracket to the vertical position, and secure with a 10-32 Torx screw. 3. Connect P615, P616, and P617. 4. Install the side panel, and close the front door. 5. Set the operator panel power switch to ON. 6. Restore the LCU; see Library Control Unit Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-26. LCU NB Card

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DC Regulator Assembly (DX or MV Card)


See Figure 6-27 on page 6-64 and use the following procedures to remove and replace the DX or MV card.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii 2. Set the operator panel power switch to OFF. 3. Open the LCU front door. 4. Loosen the spring-loaded thumbscrew on the front of the DX or MV card mounting plate that secures the regulator assembly to the frame. 5. Disconnect P30, P31, P32, P33, and P34 from their respective connectors on the DX or MV card (P34 is only found on the MV card). Note: Disconnect the connectors while removing the card from the LCU frame. 6. Slide the DX or MV card assembly out of the LCU frame.

Replacement
1. Slide the DX or MV card assembly into the frame. 2. Connect P30, P31, P32, P33, and P34 to their respective connectors on the DX or MV card. Note: P34 is found only on the MV card. 3. Secure the regulator assembly to the frame with the spring-loaded thumbscrew. 4. Close the LCU front door. 5. Set the operator panel power switch to ON. 6. Restore the LCU; see Library Control Unit Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-27. DX or MV Card

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LSM Components4410/9310/L5510

LSM Components4410/9310/L5510
Components for the 4410/9310/L5510 LSMs are described in the following sections.

REI Printed Circuit Cards (4410 Only)


See Figure 6-28 on page 6-66 and use the following procedures to remove and replace a printed circuit card in the REI card cage.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 2. See LSM Entry Procedure on page xliv. 3. Set the LCU operator panel power switch to OFF to remove the voltage from the REI card cage. 4. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 5. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during the installation of the LSM. 6. Rotate the theta arm until the card cage cover faces the inner doorway. 7. Remove the card cage cover. 8. Pull both card ejectors away from the card to release the card from the motherboard connector. 9. Remove the card by holding it on the top and bottom and gently sliding it out of the card slot.

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Figure 6-28. REI Printed Circuit Cards (4410 Only)

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Replacement
1. Ensure that there is no damage to the connector and connector pins on the card and card slot. 2. Holding the card ejectors away from the card, gently slide the card into the correct slot, making sure it is properly seated in the card receptacle. CAUTION: Component damage: Do not force the card into the slot. If excessive force is required, remove the card and reinspect for possible damage to the pins and receptacle. 3. Press the card ejectors toward the card, latching the card into the card cage. 4. Install the card cage cover. 5. Close, align, and secure the inner door. Use the alignment marks to position the door. 6. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 7. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 8. Set the LCU operator panel power switch to ON. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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REI Motherboard (4410 LM Card)


This procedure is only applicable to the 4410 LSM. See Figure 6-29 on page 6-69 and use the following procedures to remove and replace the REI motherboard.

Removal
1. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 2. See LSM Entry Procedure on page xliv. 3. Set the LCU operator panel power switch to OFF to remove the voltage from the REI card cage. 4. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 5. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during the installation of the LSM. 6. Rotate the theta arm until the card cage cover faces the inner doorway. 7. Remove the card cage cover. 8. Back the printed circuit cards halfway out of the card cage. 9. Disconnect P705, P706, P707, P708, P709, P710, P711, P712, P713, P714, P715, and P719 from the motherboard connectors. 10. Remove the 16 Torx screws securing the motherboard to the card cage.

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Figure 6-29. REI Motherboard (4410 LM Card)

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Replacement
1. Align the motherboard holes with the card cage. 2. Thread, but do not tighten, the 16 Torx screws. The cable tie mount is installed on the center left-hand screw. 3. Connect P705, P706, P707, P708, P709, P710, P711, P712, P713, P714, P715, and P719 to their respective motherboard connectors. 4. Insert and seat the outside printed circuit card on each side of the card cage. 5. Tighten the 16 Torx screws to secure the motherboard to the card cage. 6. Insert the remaining printed circuit cards. 7. Install the card cage cover. 8. Close, align, and secure the inner door. Use the alignment marks to position the door. 9. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 10. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 11. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Temperature Sensor (4410 BY Card, REI)


The REI temperature sensor is located on top of the REI card cage. Use the following procedures to remove and replace the sensor.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 4. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during the installation of the LSM. 5. Rotate the theta arm to position the card cage in the inner doorway. 6. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 7. Disconnect the leads from the temperature sensor. 8. Unsnap the temperature sensor mounting clips from the card cage.

Replacement
1. Snap the temperature sensor clips to the rails on the card cage in the same location as the one removed. 2. Connect the two spade lug leads to the temperature sensor. 3. Close, align, and secure the inner door. Use the alignment marks to position the door. 4. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 5. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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REI Card Cage Fan Cable Assembly (4410)


See Figure 6-30 on page 6-73 and use the following procedures to remove and replace one of the card cage fan cable assemblies.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 3. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during the installation of the LSM. 4. Rotate the theta arm to position the card cage in front of the inner doorway. 5. Disconnect P724 from the defective fan. Note: Use care when removing the screws from the fan in the following step to prevent the spacers located between the fan ears from falling out. 6. Remove the four 6-32 x 1.5-in. Torx screws that secure the fan and fingerguard to the REI plenum fan plate. 7. Keep the screws, spacers, and fingerguard for installing the new fan.

Replacement
1. Position the fan with the fingerguard located on the bottom onto the REI plenum fan plate. 2. Thread four 6-32 x 1.5-in. Torx screws through the fingerguard, spacers, and fan into the fan plate and tighten securely. 3. Connect P724 to the respective fan connector. 4. Close, align, and secure the inner door. Use the alignment marks to position the door. 5. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 6. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-30. REI Card Cage Fan Cable Assembly

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PLS/PLF Module (9310/L5510 Only)


See Figure 6-31 on page 6-75 and use the following procedures to remove and replace either PLS/PLF module located on the theta arm. Note: The L5510 LSM uses the PLF module instead of the PLS module.

Removal
1. See LSM Entry Procedure on page xliv. 2. Unlatch the applicable PLS/PLF module by releasing the latch ratchet at the top of the latch handle and pulling out at the top of the latch handle. 3. Slide the PLS/PLF module assembly out of the PLS/PLF mount plate.

Replacement
1. Slide the PLS/PLF module assembly into the PLS/PLF mount plate. 2. Position the latch into the slot of the PLS/PLF mount plate, and move the latch handle up to latch the PLS/PLF module assembly in place. 3. Ensure that the latch ratchet secures the top of the latch handle. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-31. PLS/PLF Module

PLS/PLF MODULES

THETA ARM

LATCH HANDLE

PLSPLF LATCH ASSEMBLY

NOTE: 1 To remove the PLS/PLF modules slide the respective modules in the direction indicated by the arrows.

VIEW A
BOTTOM VIEW PLS MOUNT PLATE

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PLR Card (9310/L5510 Only)


See Figure 6-32 on page 6-77 and use the following procedures to remove and replace the PLR card located on the theta arm.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door. 3. See the PLS/PLF module removal procedure (page 6-74), and remove both PLS/ PLF module assemblies. 4. Disconnect theta flex coil harness connectors P705, P706, P710, P722, and P723. 5. Remove and retain the screw attaching the ground lead to the PLS/PLF support bracket. 6. Disconnect the Z motor, tach, and Z flex circuit cable connectors P707, P708, P709, P711, P712, and P713 from the PLR card. 7. Remove the five screws attaching the PLR card to the PLS/PLF mount plate.

Replacement
1. Attach the PLR card to the PLS/PLF mount plate using the five screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect all cable connectors to their respective PLR card connectors. 4. Attach the theta flex coil harness ground lead to the PLS/PLF support bracket using the screw previously removed. 5. Tighten the screw to a torque of 1.4 Nm (12 in.-lb). 6. Insert and latch both PLS/PLF card assemblies to the PLR card; see the PLS module replacement procedure (page 6-74). 7. Close and secure the inner door. 8. Check alignment using the wall alignment fixture. 9. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-32. PLR Card

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PLS/PLF Fan Assembly (9310/L5510 Only)


See Figure 6-33 on page 6-79 and use the following procedures to remove and replace either PLS/PLF fan assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See the PLS/PLF module assembly removal procedure (page 6-74), and remove the applicable PLS/PLF module assembly. 3. Remove the four screws attaching the PLS/PLF module cover. 4. Disconnect the fan connector from the PLS/PLF card. 5. Remove the two screws attaching the fan assembly to the PLS/PLF module weldment. 6. Slide the grommet out of the slot and remove the fan assembly.

Replacement
1. Attach the fan assembly to the PLS/PLF module weldment using the two screws previously removed. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Place the grommet into the slot on the PLS/PLF module weldment. 4. Connect the fan assembly cable connector to the PLS/PLF card. 5. Attach the PLS/PLF module cover using the four screws previously removed. 6. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 7. See the PLS/PLF module replacement procedure (page 6-74), and install the PLS/ PLF module assembly. 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-33. PLS/PLF Fan Assembly (9310/L5510 Only)

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PMC Card (9310/L5510 Only)


See Figure 6-34 on page 6-81 and use the following procedures to remove and replace the PMC card located on the theta base. Note: Replace the entire theta turns counter assembly if the part number is 308424003 or lower.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Open the inner door. 4. Disconnect cable connectors P701, P702, P703, and P704 from the theta turns counter assembly. 5. Remove the four screws attaching the turns counter cover. 6. Remove the two screws attaching the card to the cover and remove the PMC card.

Replacement
1. Insert the PMC card into the cover, align the holes in the cover and card, and attach using the two screws provided with the card assembly. 2. Tighten the screws to a torque of 0.95 Nm (8 in.-lb). 3. Attach the cover to the turns counter using the four screws previously removed. 4. Tighten the screws to a torque of 3 Nm (26 in.-lb). CAUTION: See Figure 6-34 on page 6-81 to make sure that you connect P701 into J701 correctly. 5. Connect the respective cable connectors to J701, J702, J703, and J704 on the theta turns counter assembly. 6. Close the inner door and check alignment using the wall alignment fixture. 7. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-34. PMC Card (9310/L5510 Only)

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Theta Stop Card (4410 Only)


The MC card is located on the old style theta stop assembly. To determine whether the theta stop is an old or new style, check the mechanism on the bottom of the theta arm that drives the stop: If the mechanism is a gear, the stop is an old style. If the mechanism is a ring with a drive pin, the stop is a new style.

Note: The old and new theta stops are not interchangeable. See Figure 6-35 on page 6-83 and use the following procedures to remove and replace the MC card.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card.printed circuit card. 3. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 4. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during the installation of the LSM. 5. Disconnect P701 from the front of the theta stop assembly. 6. Remove the two #4 Phillips-head screws beside J701. 7. Remove the four 10-32 Torx screws (two on each side) securing the cover to the theta stop assembly. 8. Disconnect P702, P703, and P704 from the MC card connectors. 9. Remove the four screws holding the MC card to the theta stop housing.

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Figure 6-35. MC Card (4410 Only)

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Replacement
1. Align the MC card with the theta stop housing, and thread and tighten the four Torx screws to secure the card. 2. Connect P702, P703, and P704 to the MC card connectors. 3. Install the theta stop assembly cover using four 10-32 Torx screws. 4. Tighten the screws to a torque of 3 Nm (26 in.-lb). 5. Thread and tighten the two #4 Phillips-head screws beside J701. 6. Connect P701 to J701 on the front of the theta stop assembly. 7. Close, align, and secure the inner door. Use the alignment marks to position the door. 8. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 9. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Theta Stop CardMC1 Card (4410)


The MC1 card is located on the new style theta stop assembly. To determine whether the theta stop is an old or new style, check the mechanism on the bottom of the theta arm that drives the stop: If the mechanism is a gear, the stop is an old style. If the mechanism is a ring with a drive pin, the stop is a new style.

Note: The old and new theta stops are not interchangeable. See Figure 6-36 on page 6-86 and use the following procedures to remove and replace the MC1 card.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 4. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during the installation of the LSM. 5. Disconnect P701, P702, P703, and P704 from the front of the theta stop assembly. 6. Remove the two screws beside J701 attaching the cover to the MC1 card. 7. Remove the four screws holding the MC1 card to the theta stop housing.

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Figure 6-36. MC1 Card

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Replacement
1. Align the MC1 card with the theta stop housing, thread, and tighten the four Torx screws to secure the card. 2. Attach the cover to the MC1 card using the two Phillips-head screws provided with connector J701. Note: Later versions of the theta stop mechanism have a connector key attached to the cover and held in place with the two screws that attach the cover to the MC1 card. 3. Reinstall this connector key. 4. Connect P701, P702, P703, and P704 to their respective connectors on the front of the theta arm assembly. 5. Close, align, and secure the inner door. Use the alignment marks to position the door. 6. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 7. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Theta Stop Assembly (4410 Old Style)


The old and new style theta stops are not interchangeable. To determine whether the theta stop is an old or new style, check the mechanism on the bottom of the theta arm that drives the stop: If the mechanism is a gear, the stop is an old style. If the mechanism is a ring with a drive pin, the stop is a new style.

See Figure 6-37 on page 6-89 and use the following procedures to remove and replace the old style theta stop assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door, by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 3. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 4. Disconnect P701, P702, P703, and P704 from the front of the assembly. 5. Rotate the theta arm until the theta home sensor flag mounted on the theta stop gear is centered in the home sensor. 6. Remove the four 3/8-in. allen-head screws and lock washers holding the theta stop assembly to the theta base.

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Figure 6-37. Theta Stop Assembly (Old Style)

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Replacement
1. Look through the alignment slot in the side of the cover. 2. Rotate the gear on the theta stop assembly until the sensor flag edge is aligned with the scribe mark on the theta stop cover. 3. Carefully position the theta stop assembly into place while avoiding damage to the home opt sensor or flag. The theta arm must be in the home position (the home opt flag is aligned in the center of the sensor when the theta stop traveling nut is centered). 4. Insert and tighten the four 3/8-in. allen-head screws and lock washers to secure the theta stop assembly to the theta base. 5. Tighten the four screws to a torque of 18 to 23 Nm (160 to 200 in.-lb). 6. Rotate the theta arm slowly while checking for sufficient clearance between the home opt flag and sensor walls. 7. Loosen the sensor mount screws, and adjust the sensor for proper clearance if necessary. 8. Connect P701, P702, P703, and P704 to the MC card connectors. 9. Close, align, and secure the inner door. Use the alignment marks to position the door. 10. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 11. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Theta Stop Assembly (4410 New Style)


The old and new style theta stops are not interchangeable. To determine whether the theta stop is an old or new style, check the mechanism on the bottom of the theta arm that drives the stop: If the mechanism is a gear, the stop is an old style. If the mechanism is a ring with a drive pin, the stop is a new style.

See Figure 6-38 on page 6-92 and use the following procedures to remove and replace the new style theta stop assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 3. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 4. Rotate the theta arm through the home position, then rotate the arm approximately 30 degrees to the right or left to allow access for removal of the theta stop assembly. 5. Disconnect P701 and P702 from the front of the theta stop assembly. 6. Disconnect P651 and P812 from the LCU I/O panel. 7. Remove the four screws attaching the theta stop assembly to the theta base.

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Figure 6-38. Theta Stop Assembly (New Style)

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Replacement
The following procedure must be followed exactly as written to prevent damage to the theta stop ring extrusion. See Figure 6-38 on page 6-92, View A, for locations references. 1. Ensure that the theta arm is still rotated 30 degrees to the right or left of home position. 2. When installing the theta stop to the theta base (pedestal), use extreme care that the white dot on the cam star wheel remains in the next hole to the right or left of home position in the cam cover. 3. Attach the theta stop to the theta base using two 3/8-16 shoulder screws in the upper two mounting holes. 4. Attach the bottom of the theta stop to the theta base using two 3/8-16 x 5/8-in. machine screws with a lock washer on each screw. 5. Tighten the four screws to a torque of 18 to 23 Nm (160 to 200 in.-lb). 6. Connect P701 and P702 to the front of the theta stop assembly. 7. Connect P651 and P812 to the LCU I/O panel. 8. Ensure that the theta EPO/DBR cable connectors P703 and P704 are connected to J703 and J704, respectively, on the front of the MC1 card. CAUTION: Component damage: See Figure 6-39 on page 6-95, View A, for the next step. Never install the theta stop when the star cam shaft butts against the shear pins. 9. Rotate the theta arm through the home position. You will hear a distinct click when the roller falls into the detent in the next hole to the right or left of home position in the cam cover. 10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Theta Stop Shear Pin (4410 New Style Stop)


If a failure of the theta arm control circuitry occurs to the extent that the theta arm travels far enough to cause an EPO condition, the shear pin on the theta stop will be sheared off. After the electronic problem has been corrected, you must replace the shear pin on the theta arm. See Figure 6-39 on page 6-95 and use the following procedures to remove and replace the shear pin.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 3. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 4. Locate the portion of the shear pin that was broken off. 5. Rotate the theta arm until the white dot on the star cam is aligned with the hole marked home on the theta stop cover. 6. Remove the broken shear pin with a screwdriver from the bottom of the cam mount.

Replacement
1. Thread and tighten the new shear pin from the bottom into the cam mount. 2. Remove any tools from the LSM inner wall enclosure. 3. Close, align, and secure the inner door. Use the alignment marks to position the door. 4. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 5. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-39. Theta Stop Shear Pin (4410)

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Theta Home Opt Sensor and Cable Assembly (4410)


This procedure is only applicable to the 4410 LSM. The theta home opt sensor is mounted on the top right-hand side of the theta stop assembly housing (as viewed from the inner doorway). Use the following procedures to remove and replace the home opt sensor assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 4. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 5. Disconnect the theta home opt sensor cable connector P703 from the MC card. 6. Remove the two #8 Torx screws securing the theta home sensor mounting plate to the theta stop assembly housing. 7. Remove the two #6 Torx screws securing the theta home sensor to the mounting plate.

Replacement
1. Attach the home opt sensor to the mounting plate using two #6 Torx screws. 2. Attach the theta home sensor mounting plate to the theta stop assembly housing using two #8 Torx screws. 3. Connect theta home sensor cable connector P703 to the MC card. 4. Move the theta arm slowly, and observe the clearance between the theta home opt sensor flag and the sensor. If the flag is not centered in the switch as it passes through it, loosen the two screws in the home sensor mounting plate, and move it to the proper position and tighten the two screws. 5. Close, align, and secure the inner door. Use the alignment marks to position the door. 6. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side.

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7. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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LSM Interlock Card (MG Card)


See Figure 6-40 on page 6-100 and use the following procedures to remove and replace the MG card, which is located in the header of the access door frame. Note: If you are going to replace the HBO sensor/switch, perform that task first (see HBO Sensor/Switch AssemblyDoor on page 6-342), and return to this procedure when you are instructed to do so.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Remove eight Torx screws from the header cover and put the screws and cover aside. 4. If the MG card you are removing is an old-style card (4-connector, PN 4101800xx), disconnect J800, J801, J802, and J803 from the card. If the MG card you are removing is a new-style card (7-connector, PN 4101800xx), disconnect J800, J801, J802, and J803 from the MG card. If connectors J825, J1, and J804 on the MG card have corresponding plugs P825, P1, and P804 attached, remove these plugs from the card. 5. Remove the six Torx screws holding the card to the door frame header, and remove the MG card.

Replacement
1. Install the card with the connectors as a reference. J875 and J804 should be toward the side where the HBO switch mounts (hinge side of the door). Use the six Torx screws that you removed in Step 5 of the removal procedure to attach the card to the header. 2. If the HBO sensor/switch on the LSM is an old style, mechanical sensor (PN 4102707xx), connect J800, J801, J802, and J803 to the corresponding connectors on the MG card. If the HBO sensor is a new style, electronic sensor (PN 411085xx), connect P804 from the HBO sensor to J804 on the MG card, and connect P800, P801, P802, P803, P875, and P1 to the corresponding jacks on the MG card. 3. If you replaced the HBO sensor/switch along with the MG card, return to Step 6 of the HBO replacement procedure in HBO Sensor/Switch Assembly Door on page 6-342 at this time. 4. Replace the header cover with the eight screws previously removed. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb).

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6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-40. MG Card

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Pinning Procedure4410 Z Channel


This applies only to the 4410 Z channels. When work is being accomplished on components located on the turntable or certain parts of the Z channel, it is desirable to position the turntable at approximately waist height. Provisions have been made to pin the mechanism (both leadscrew-driven and belt-driven styles) to this position. See the appropriate portion of Figure 6-41 on page 6-102 for the type of Z channel being pinned. 1. For the leadscrew-driven Z channel: a. Move the Z arm down until the counterweight plate is above the bottom pinning hole in the Z channel (if the weight of the counterweights must be removed from the cable).

b. Insert the ball locking pin through the Z channel hole. c. Lower the Z arm to the desired position.

d. Move the Z arm until the nearest hole in the leadscrew aligns with the pinning hole in the lower bearing plate. e. Insert the ball locking pin into the hole.

For the belt-driven Z channel: a. Lower the Z channel until the rear counterweight is above the second pinning hole from the bottom of the Z channel if the weight of the counterweights need to be removed from the belt.

b. Insert a ball locking pin through the Z channel below the counterweight. c. Lift the Z arm and insert a ball locking pin in the second pinning hole from the top of the Z channel.

d. Lower the Z arm to rest the Z roller bracket on the ball locking pin. 2. Remove the pins when the removal and replacement procedure has been completed. 3. Move the Z arm from limit to limit to check for unobstructed travel. 4. Remove the two screws securing the hand to the turntable from the bottom of the hand.

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Figure 6-41. Pinning Locations of 4410 Z Channel

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Turntable Interface Card (4410 MB Card)


The 4410 MB card is mounted on the Z arm. See Figure 6-42 on page 6-104 and use the following procedures to remove and replace the MB card.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 4. Disconnect P740, P741, P742, and P743 from the MB card connectors. 5. Remove four #6 Torx screws that secure the MB card to the Z arm.

Replacement
1. Attach the MB card to the Z arm using four #6 Torx screws. 2. Connect P740, P741, P742, and P743 to their respective connectors on the MB card. 3. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-42. MB Card (4410)

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Gripper Assembly (4410 Only)


This FRU includes bearings, coil cord, stepper motor, and MA card. See Figure 6-43 on page 6-106 and use the following procedures to remove and replace the gripper assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 4. Remove two screws connecting the coil cord bracket to the back of the roll pulley. 5. Disconnect P779 from the MD card (if the newer style MD card is installed, unscrew the cable clamp on the roll card bracket and then disconnect P779). 6. Remove two #4 Torx screws from the front plate, being careful not to lose the bearing and five washers on the older style plate or the one wave washer on the newer style plate. Note: If the parts fall out, put them back into the plate in the following order: wave, flat, wave, flat, wave, and bearing (see Figure 6-43 on page 7-106). 7. Pull the reach shafts out through the front of the hand assembly and gripper assembly. 8. Guide P779/coil cord bracket/coil cord through the hole in the roll pulley and toward the gripper assembly. 9. Carefully slide the gripper assembly off the leadscrew, making sure that the flags on the assembly clear the sensors on the MK card. 10. Remove the two screws attaching the reach leadscrew nut to the bottom of the gripper assembly, and remove the nut, being careful that the spring does not fall from the nut.

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Figure 6-43. Gripper Assembly (4410)

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Replacement
1. Use the two screws to install the nut with the spring onto the carriage of the new gripper assembly. 2. Insert the leadscrew into the leadscrew nut of the gripper assembly. 3. Guide the P779/coil cord bracket/coil cord back through the roll pulley, and connect P779 to the MD card. If the newer card is installed, attach the cable clamp onto the roll card bracket. 4. Connect the coil cord bracket to the roll pulley with two screws. 5. Clean the reach shafts with a lint-free cloth. Do not lubricate any component on the hand assembly. 6. Insert the reach shafts through the hand assembly and gripper assembly. 7. Fit the leadscrew into the front plate bearing, and attach the front plate with two screws. 8. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Gripper Assembly (9310 Only)


See Figure 6-44 on page 6-108 and use the following procedures to remove and replace the gripper on the 9310 turntable assembly. Note: The L5510 gripper assemblies cannot be removed and replaced. If a gripper is defective the L55510 turntable must be replaced.

Removal
1. See LSM Entry Procedure on page xliv. 2. Position the transport to approximately waist height. 3. Extend the gripper by grasping and pulling out on the fingers. 4. Depress the ears on the gripper spring clip, release the gripper spring clip from the reach carriage, and slide the gripper free of the hand.

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Figure 6-44. Gripper Assembly (9310)

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Replacement
Note: Make sure that the gripper identification label is facing away from the camera to avoid targeting errors. 1. Align the gripper solenoid armature with the solenoid coil, and slide the gripper into the hand. 2. Depress the ears on the gripper spring clip, align the clip to attach the spring clip to the reach carriage, and release. 3. Make sure that all four tabs on the gripper spring clip are in the slots on the reach carriage. 4. Replace the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Cartridge Fingers (4410 Only)


See Figure 6-45 on page 6-110 and use the following procedures to remove and replace the top or bottom finger on the finger subassembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Remove the top screw attaching the top finger block to the gripper carriage (for the top cartridge finger), or remove the top and bottom screws attaching the top and bottom finger blocks to the gripper carriage (for the bottom cartridge finger). 4. Extend and separate the fingers to gain access to the two finger screws. 5. Remove these screws on the cartridge finger, and lift the finger and shims off the dowel pins on the finger block.

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Figure 6-45. Cartridge Fingers (4410)

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Replacement
1. Insert the shims previously removed between the replacement finger and the finger block, aligning with the two dowel pins. 2. Align the cartridge finger onto the dowel pins on the finger block. 3. Attach the finger to the finger block with the two screws previously removed. 4. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 5. Attach the finger block(s) to the carriage gripper with the screw(s) previously removed. 6. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 7. Check the distance between the fingers using the following procedure: a. Close the fingers completely by manually turning the step motor.

b. Locate the finger gauge, PN 4106933xx, in the Installation Tool Kit and place the thin part between the fingers. If the thin part does not fit, remove shims until it does. It should move but not be loose. c. Take the thick part of the gauge and attempt to slide it between the closed fingers. If the block fits between the fingers without resistance, the fingers are too far apart and the shims must be increased.

d. Clean the reach linear shaft with a lint-free cloth. Do not lubricate any component on the hand assembly. e. f. Remove the locking pin(s) from the Z channel assembly and move the Z arm from limit to limit to check for unrestricted movement. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Roll Interface Card (4410 Only)


See Figure 6-46 on page 6-113 (old style) or Figure 6-47 on page 6-114 (new style) and use the following procedures to remove and replace the MD card located on the hand assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 4. Remove the two screws from the component side of the MD card that attach the MD card cable clamp and cables to the MD card. 5. Disconnect P775, P776, P777, P778, P779, P780, and P781 from the MD card. 6. Remove the screw from the top of the roll card bracket. 7. Remove the screw attaching the cable clamp to the side of the roll card bracket. 8. Remove the two screws attaching the roll card bracket to the roll pulley flange. 9. Remove the three screws attaching the MD card to the roll card bracket.

Replacement
1. Attach the MD card to the roll card bracket. 2. Attach the roll card bracket to the roll pulley flange. 3. Attach the cable clamp to the side of the roll card bracket. 4. Thread and tighten the screw into the top of the roll card bracket. 5. Connect P775, P776, P777, P778, P779, P780, and P781 to the MD card. 6. Attach the MD card cable clamp and cables to the MD card. 7. Remove locking pin(s) from Z channel assembly, and move Z arm from limit to limit to check for unrestricted movement. 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-46. MD Card (4410 Old Style)

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Figure 6-47. MD Card (4410 New Style)

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Z Sensor Card (4410 ME Card)


There are five ME cards located on the right-hand side of the leadscrew-driven Z channel assembly and only three on the belt-driven Z channel assembly. See Figure 6-48 on page 6-116 (for the leadscrew-driven Z channel) or Figure 6-49 on page 6-117 and Figure 6-50 on page 6-118 (for the belt-driven Z channel) and use the following procedures to remove and replace one of the ME cards.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Disconnect P727-X from the defective ME card. The ME card location is designated as follows: Top Second from top Middle Second from bottom Bottom Crash Stop 2 Warning 2 (not on belt-driven Z channel) Home position Warning 1 (not on belt driven Z channel) Crash Stop 1

4. If there is a cover over the ME card, remove the two screws attaching the cover to the ME card mount. Retain the cover and screws for reattachment. 5. Remove the three #4 Torx screws attaching the ME card assembly to the sensor card mount.

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Figure 6-48. ME Card (Sheet 1 of 3)

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Figure 6-49. ME Card (Sheet 2 of 3)

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Figure 6-50. ME Card (Sheet 3 of 3)

Replacement
1. Secure the ME card assembly to the sensor card mount using three #4 Torx screws. 2. Connect P727-X to the ME card connector. 3. Carefully move the Z arm in and out of its limits of play while checking the flag for proper clearance through the ME card sensors. If the flag does not clear the sensors, perform the following steps to adjust the sensors (see Figure 6-50). a. Loosen the two screws securing the sensor card mount to the Z channel and move the Z arm up and down so that the flag is in the sensor but does not hit the sensor. The Z arm is spring-loaded so that, if it is released, it is forced outward from the center of the LSM. The Z arm must be in this position while making the sensor adjustments.

b. Adjust the ME card so that there is a 0.51-mm (0.020-in.) gap between the inside edge of the flag and the sensor (the flag is not centered between the sensors).

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c.

Tighten the two screws securing the sensor card mount to the Z channel.

d. Again, move the Z arm in and out of its limits of play to check that the flag clears the sensors. 4. If an ME card cover was removed in a previous removal step, attach the cover using the two screws previously removed. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Z Sensor Flag (4410 Belt-Driven Z)


This procedure applies only to the 4410 belt-driven Z channel. See Figure 6-51 on page 6-120 and use the following procedures to remove and replace the Z sensor flag.

Removal
1. See LSM Entry Procedure on page xliv. 2. Move the Z arm down to a position to gain access to the screw attaching the Z sensor flag to the back of the Z arm. 3. Remove the screw and Z sensor flag.

Replacement
1. Align the Z sensor flag holes with the pins and screw hole on the back of the Z arm. 2. Attach the sensor flag with the screw previously removed. 3. Tighten the screw to a torque of 3 Nm (26 in.-lb). 4. Carefully move the Z arm while checking the travel of the sensor flag through each of the ME card sensors. Adjust the sensor card mount if the flag is not centered in its travel through the sensor.

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Figure 6-51. Z Sensor Flag (4410)

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Reach Sensor MK Card (4410 Only)


See Figure 6-52 on page 6-122 and use the following procedures to remove and replace the MK card.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 4. Remove the four #2 pan-head screws attaching the MK card to the reach sensor bracket. 5. Disconnect P783 from J783.

Replacement
1. Attach the MK card to the reach sensor bracket with four #2 pan-head screws. 2. Connect P783 to J783. 3. While looking from the front of the hand, pull the reach mechanism toward the front (duplicating reach extended). 4. Verify that the flag located on the side of the reach assembly travels through the center of the three sensors. If not, loosen the four MK mounting screws, center the sensor flag in the sensors, and tighten the screws. 5. Repeat the previous step to verify correct alignment. 6. Clean the linear rods using a dry lint-free cloth. Do not lubricate any component on the hand assembly. 7. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-52. MK Card (4410)

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Theta Flex Coil Harness


The theta flex coil harness is the same electrically for both the 4410 and the 9310/L5510. However, the lower end connections are attached to the PLR Card on the 9310/L5510 and to the REI card cage on the 4410. The upper connections are attached identically on the lower roof gusset bracket for both models. See Figure 6-53 on page 6-124 and Figure 6-54 on page 6-125 and use the following procedures to remove and replace the theta flex coil harness.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door. 3. Disconnect P852, P853, P854, and coaxial cable BNC connectors P851 and P850 from their respective connectors at the roof gusset. 4. Remove the strain relief screw attaching the ground lead round terminal lug. 5. If the LSM is a 4410: a. Disconnect the two coaxial cable BNC connectors P723 and P722 from the theta coil cord support.

b. Remove the screw attaching the ground lead round terminal lug to the strain relief on the coil cord support. c. Cut the four cable ties securing the cables to the REI tie mounts.

d. Disconnect P705, P706, and P710 from the motherboard. e. Remove the other three Torx screws from the coil cord strain relief securing the flex coil cable to the theta coil cord support.

If the LSM is a 9310/L5510: a. Disconnect P722 and P723 coaxial connectors from the PLR card connectors.

b. Disconnect P705, P706, and P710 connectors from the PLR card connectors. c. Remove the four Torx screws attaching the cable and strain relief to the PLS/PLF support bracket.

d. Remove and retain the screw attaching the ground lead to the PLS/PLF support bracket. 6. Remove the other three Torx screws from the coil cord strain relief securing the flex coil to the roof gusset.

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Figure 6-53. Theta Flex Coil Harness (Sheet 1 of 2)

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Figure 6-54. Theta Flex Coil Harness (Sheet 2 of 2)

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Replacement
1. Insert the flex coil cable end having connectors P852, P853, P854, P851, P850, and the ground lead terminal into the strain relief of the roof gusset. 2. Attach the clamp portion of the strain relief over the cable, and secure with three of the Torx screws. 3. Leave a sufficient amount of cable to connect the cable connectors to their respective connectors on the gusset bracket. 4. Attach the ground lead round terminal lug to the strain relief with the fourth screw. 5. Attach connectors P850, P851, P852, P853, and P854 to their respective connectors on the roof gusset bracket. 6. If the LSM is a 4410: a. Position the theta arm to the home position (the Z channel is in the center of the access door opening).

b. With the coil cable in its natural coiled position (eight coils), place it into the strain relief located on the theta coil cord support. c. Attach the clamp over the cable and secure it to the strain relief with four Torx screws. The ground cable is attached to one of the screws. Allow sufficient cable length to permit connecting to the motherboard.

d. Connect the two coaxial cable BNC connectors P723 and P722 to their respective jacks on the coil cord support and P705, P706, and P710 to J705, J706, and J710 on the REI motherboard. e. Secure the cables to the tie mounts with four cable ties.

If the LSM is a 9310/L5510: a. Position the theta arm to the home position (Z Column 0 in front of the access door).

b. With the coil cable in its natural coiled position, place it into the strain relief located on the PLR card support. Note: The theta flex coil harness should have eight coils in it when it is in the home position. The theta turns counter should also be rotated until the 0 on the turn counter label is at the top. c. Attach coaxial cable connectors P722 and P723 to their respective connectors on the PLR card.

d. Attach cable connectors P705, P706, and P710 to their respective connectors on the PLR card. e. Attach the clamp portion of the strain relief over the cable and secure it with the four Torx screws.

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f.

Attach the ground lead spade lug to the PLS/PLF support bracket using the screw previously removed.

7. Tighten the eight screws in the strain reliefs to a torque of 3 Nm (26 in.-lb). 8. Rotate the theta turns counter to the home position, if not previously done. 9. Close and secure the inner door. 10. Check the alignment using the wall alignment fixture. 11. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Theta Arm Assembly (9310/L5510 Only)


The procedure for removing and replacing the theta arm assembly involves removing the following: Inner upper wall Panel 12 Two turntable assemblies Two Z columns Six cables from the theta arm Two PLS/PLF module assemblies (The PLF modules are for the L5510 LSM) PLS/PLF mount plate and PLR card Theta arm

See each section called for in the removal of assemblies to gain access to the theta arm. Then return to this section, see Figure 6-55 on page 6-130 through Figure 6-57 on page 6-132 and use the following procedures to remove and replace the 9310/L5510 theta arm assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove any customer cartridges from upper inner wall Panel 12 or have the customer perform this task. 3. Mark the location of the upper inner wall Panel 12 for relocation purposes when re-installing it later. 4. Remove the bolts attaching upper inner wall Panel 12 to the LSM floor and the adjacent panels at the bottom. 5. Remove the panel from the LSM. 6. Open the inner door. 7. Remove the turntable assembly from each Z column; see the removal procedure in Turntable Assembly (9310/L5510 Only, Din Connector) on page 6-176.

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8. Disconnect the Z motor power and encoder cables and the Z flex circuit from the PLR card, and free them from the Z flex and motor cable tray on the theta arm. Tape the Z motor and tach cables to the Z column. 9. Remove the Z flex circuit from the Z flex support bracket on each Z column transport. 10. Remove the Z flex circuit from the Z flex weldment bracket on the end of each theta arm and remove the Z flex circuit from the LSM. 11. Remove the Z column from each end of the theta arm; see the removal procedure in Z Column Assembly (9310/L5510 Only) on page 6-195. 12. Disconnect the theta flex coil harness from the PLR card connectors P/J 705, 706, 707, 722, and 723. 13. Remove the two PLS/PLF module assemblies; see the removal procedure in PLS/ PLF Module (9310/L5510 Only) on page 6-74. 14. Remove the two screws securing the PLS/PLF mount plate to the PLS/PLF support bracket. 15. Rotate the PLS/PLF mount plate counterclockwise to release the pins from the keyholes, and lift the mount plate free from the support bracket. 16. Remove and retain the four screws attaching the theta flex coil harness strain relief to the PLS/PLF support bracket. 17. Remove and retain the screw attaching the flex coil harness ground lead to the PLS/PLF support bracket. 18. Secure the flex coil harness aside to an upper inner wall so it does not interfere with the removal of the theta arm. 19. Remove the eight screws attaching the theta turntable to the theta motor and carefully remove the theta arm from the LSM enclosure.

Replacement
1. Attach the theta arm turntable to the theta motor using the eight screws previously removed. 2. Tighten the screws to a torque of 5 Nm (45 in.-lb). 3. Place the PLS/PLF mount plate keyholes over the pins on the support bracket. 4. Rotate the PLS/PLF mount plate clockwise to lock the pins in the slots. 5. Secure using the two screws previously removed. 6. Tighten the screws to a torque of 3 Nm (26 in.-lb). 7. Connect the theta flex coil harness connectors P705, 706, 707, 722, and 723 to the PLR card respective connectors.

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8. Attach the flex coil harness ground wire to the PLS/PLF support bracket using the screw previously removed. 9. Tighten the screw to a torque of 1.4 Nm (12 in.-lb). 10. Secure the theta flex coil harness to the PLS/PLF support bracket using the strain relief and screws previously removed. 11. Tighten the screws to a torque of 3 Nm (26 in.-lb). Note: The theta flex coil harness should have eight coils in it when it is in the home position. The theta turns counter should also be rotated until the 0 on the turn counter label is at the top. 12. Install the two PLS/PLF module assemblies; see PLS/PLF Module (9310/L5510 Only) on page 6-74. 13. Attach the two Z columns to the theta to Z transition brackets on the end of the theta arm; see Z Column Assembly (9310/L5510 Only) on page 6-195. 14. Route the two Z flex circuits, Z motor power, and encoder cables through the Z flex and motor cable tray on the side of the theta arm. 15. Attach the two Z flex circuits to the PLR card, Z flex support brackets on the transport, and Z flex weldment brackets on the theta arm. 16. Connect the Z motor power and encoder cables to the respective connectors on the PLR card. 17. Install a turntable assembly on each transport; see Turntable Assembly (9310/ L5510 Only, Din Connector) on page 6-176. 18. Install the upper inner wall Panel 12 using the location marks and screws previously removed. 19. Tighten the screws to a torque of 20 to 24 Nm (180 to 216 in.-lb). 20. Close and secure the inner door. 21. Check the alignment using the wall alignment fixture. 22. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 23. Attach the wall alignment tool to the transport, and check the alignment of the inner upper Wall 12 and the inner door. 24. Adjust the wall and the door, if they are out of tolerance. 25. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

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Figure 6-55. Theta Arm Assembly (9310/L5510 Only) (Sheet 1 of 3)

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Figure 6-56. Theta Arm Assembly (9310/L5510 Only) (Sheet 2 of 3)

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Figure 6-57. Theta Arm Assembly (9310/L5510 Only) (Sheet 3 of 3)

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Z Flex Circuit Assembly (9310/L5510 Only)


See Figure 6-58 on page 6-135, Figure 6-59 on page 6-136, and Figure 6-60 on page 6-137 and use the following procedures to remove and replace the Z flex circuit assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door for access to the theta arm. 3. Disconnect the Z flex connector from J712 or J713 on the PLR card. 4. Remove the four screws attaching the Z flex to the Z flex support bracket on the Z transport assembly. 5. Release the connector that is on the end of the Z flex circuit from the connector on the transport flex assembly. CAUTION: Component damage: In the next step, make sure you do not damage the shield between the flex circuit and the flex circuit guide. (In older versions, there might not be a shield between the flex circuit and guide.) 6. Remove the Z flex circuit from the Z flex weldment bracket on the theta arm. Note: The circuit is attached to the bracket with a spring-loaded retaining bar. Do not use a tool to do this. Do not remove the shield, if there is one. 7. Free the Z flex from the Z flex cable tray on the side of the theta arm.

Replacement
1. Connect the Z flex circuit and PLR card connectors P/J713 (Hand 1) or P/J 712 (Hand 0). 2. Route the Z flex circuit through the cable tray on the side of the theta arm. 3. Position the Z flex circuit through the Z flex guide bracket as shown in Figure 6-59 on page 6-136, and place the keyhole slots of the flex circuit over the spring-loaded bracket shoulder screws. 4. If necessary, place the end of the shield with the keyhole slots over the corresponding holes in the flex circuit (see Figure 6-59 on page 6-136). 5. Slide the keyhole slots down over the screw head(s). 6. Secure the Z flex to the Z flex bracket pin with the Z flex retainer. 7. Connect the connector on the end of the Z flex circuit to the connector on the transport flex assembly at the Z flex support bracket.

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8. Secure the shield and the Z flex circuit assembly to the Z flex support bracket using the four 10-32 x 1/2-in. Torx screws previously removed. 9. Tighten the screws to a torque of 3 Nm (26 in.-lb). 10. Check the inner door alignment using the wall alignment fixture. 11. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-58. Cables (9310/L5510 Only) (Sheet 1 of 3)

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Figure 6-59. Z Cables (9310/L5510 Only) (Sheet 2 of 3)

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Figure 6-60. Z Cables (9310/L5510 Only) (Sheet 3 of 3)

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Z Motor Encoder Cable (9310/L5510 Only)


See Figure 6-58 on page 6-135, Figure 6-59 on page 6-136, and Figure 6-60 on page 6-137 and use the following procedures to remove and replace the Z motor encoder cable.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door. 3. Disconnect the Z motor encoder cable connector P725 from the connector on the Z column cap assembly. 4. Free the cable from the raceway on the back of the Z column. 5. Free the cable from the Z flex and motor cable tray on the theta arm. 6. Disconnect the Z motor encoder cable connector P709/P711 from the PLR card connector.

Replacement
1. Connect the Z motor encoder cable connector P725 to the connector on the Z column cap assembly. 2. Route the cable through the raceway on the back of the Z column. 3. Route the cable through the Z flex and motor cable tray on the theta arm. 4. Connect the cable connector P709/P711 to the connector on the PLR card. 5. Close and secure the inner door. Check the alignment using the wall alignment fixture. 6. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 7. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

Z Motor Power Cable (9310/L5510 Only)


See Figure 6-58 on page 6-135, Figure 6-59 on page 6-136, and Figure 6-60 on page 6-137, and perform the following procedures to remove and replace the Z motor power cable.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door.

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3. Disconnect the Z motor power cable connector P720 from the connector on the Z column cap assembly. 4. Free the cable from the raceway on the back of the Z column. 5. Free the cable from the Z flex and motor cable tray on the theta arm. 6. Disconnect the Z motor power cable connector P707/P708 from the PLR card connector.

Replacement
1. Connect the Z motor power cable connector P720 to the connector on the Z column cap assembly. 2. Route the cable through the raceway on the back of the Z column. 3. Route the cable through the Z flex and motor cable tray on the theta arm. 4. Connect the cable connector P707/P708 to the connector on the PLR card. 5. Close and secure the inner door. Check the alignment using the wall alignment fixture. 6. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 7. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

Theta Counter Shear Pin (9310/L5510 Only)


See Figure 6-61 on page 6-141 and use the following procedures to remove and replace the theta counter shear pin.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door. 3. Remove the screw attaching the shear pin clamp to the theta turntable. 4. Remove the theta turns counter shear pin from the theta turntable by pushing the shear pin from the bottom.

Replacement
1. Insert the theta turns counter shear pin into the theta turntable with the pin pointing down. 2. Attach the shear pin clamp over the shear pin and secure with the screw previously removed. 3. Tighten the screw to a torque of 3 Nm (26 in.-lb).

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4. Close and secure the inner door. Check the alignment using the wall alignment fixture. 5. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 6. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

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Figure 6-61. Theta Counter Shear Pin (9310/L5510 Only)

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Theta Turns Counter Assembly (9310/L5510 Only)


See Figure 6-62 on page 6-143 and use the following procedures to remove and replace the 9310/L5510 theta turns counter assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door. 3. Disconnect cable connectors P701, P702, P703, and P704 from the theta turns counter PMC card. 4. Remove the four screws attaching the theta counter cover to the theta turns counter. 5. Remove the two screws attaching the theta turns counter assembly to the theta motor housing.

Replacement
1. Attach the theta turns counter to the theta motor using the two screws previously removed. 2. Tighten the screws to a torque of 5 to 7 Nm (45 to 60 in.-lb). 3. Attach the theta counter cover to the theta turns counter using the four screws previously removed. 4. Tighten the screws to a torque of 3 Nm (26 in.-lb). 5. Connect cable connectors P701, P702, P703, and P704 to the respective connectors on the bottom of the theta turns counter assembly. 6. Turn the theta counter drum cam to the home position (the center groove on the cam is on top). 7. Close the inner door. Check the alignment using the wall alignment fixture. 8. Tighten the screws securing the door to a torque of 32.5 to 38 Nm (288 to 336 in.-lb). 9. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

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Figure 6-62. Theta Counter Assembly (9310/L5510 Only)

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Theta Motor Assembly (9310/L5510 Only)


The procedure for removing and replacing the theta motor assembly involves all the steps completed in removing and replacing the theta arm plus disconnecting and removing the motor. WARNING: LIfting hazard: Because of the weight of the motor assembly, two persons are required to lift the motor assembly. See Figure 6-63 on page 6-146 and use the following procedures to remove and replace the theta motor assembly:

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the theta arm; see the theta arm removal procedure in Theta Arm Assembly (9310/L5510 Only) on page 6-127 and complete all the steps. 3. Disconnect the theta motor power cable connector P700 from the theta motor. 4. Disconnect the theta motor encoder, EPO, and theta sensor cable connectors P701, P702, and P704 from the theta turns counter PMC card. 5. Remove the theta turns counter from the theta motor; see the removal procedure in Theta Turns Counter Assembly (9310/L5510 Only) on page 6-142. 6. Remove the eight screws attaching the theta motor to the theta base. WARNING: Lifting hazard: The 9310/L5510 theta motor assembly weighs approximately 56.25 kg (125 lb) and is awkward to handle. Because of the weight of the theta motor and the awkward position for removing and replacing it, the theta motor assembly removal requires two persons. Use extreme care while moving it into and out of the LSM; otherwise, personal injury and damage to equipment can occur. 7. Carefully lift the theta motor and, remove it from the LSM.

Replacement
1. Lift the theta motor and position on top of the theta base with the larger hole in the motor aligned with the alignment hole in the theta base. 2. Attach the theta motor to the base using the eight screws and lock washers previously removed. 3. Tighten the screws to a torque of 32.5 to 38 Nm (288 to 336 in.-lb).

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4. Attach the theta turns counter to the theta motor; see the replacement procedure in Theta Turns Counter Assembly (9310/L5510 Only) on page 6-142. 5. Connect the theta motor power cable connector P700 to the theta motor connector J700. 6. Connect the encoder cable connector P702 to the PMC card. 7. Connect the EPO cable connector P704 to the PMC card. 8. Connect the theta sensors cable connector P701 to the PMC card. 9. Install the theta arm, Z columns, turntables, and cables; see the replacement procedure in Theta Arm Assembly (9310/L5510 Only) on page 6-127. 10. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

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Figure 6-63. Theta Motor Assembly (9310/L5510 Only)

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Theta Encoder Assembly (9310/L5510 Only)


See Figure 6-64 on page 6-149 and use the following procedures to remove and replace the 9310/L5510 theta encoder. Notes: 1. The torque tool supplied with the replacement encoder assembly has been pre-set to the proper torque value at the factory. Use it in Step 4 of the removal procedure and Step 5 of the replacement procedure (page 7-148). 2. Do not attempt to adjust the tool or change its setting.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door. 3. Disconnect the theta motor encoder cable connector P702 from the theta turns counter PMC card; see Figure 6-64 on page 6-149, View A. CAUTION: Packaging damage: Do not damage the packaging in which the new encoder assembly and torque tool were packed. You will pack the defective encoder and the torque tool in it when you return them to the factory. 4. With the torque hex wrench shipped with the theta motor, loosen the top set screw in the flex coupling to free the coupling from the theta encoder coupling plate. 5. Remove the four screws attaching the theta encoder coupling plate to the theta motor rotor, and lift the plate free. Set the coupling plate and four screws aside for later use. 6. Remove the three screws attaching the encoder mounting plate to the theta motor housing. Set the three screws aside for later use. 7. Lift the mounting plate with the attached theta motor encoder out of the theta motor. CAUTION: Component damage: Be careful not to damage the cable.

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Replacement
1. Locate the new theta encoder assembly. Route the encoder cable through the cable access opening in the theta motor housing as you lower the encoder into the motor. 2. Secure the theta encoder mounting plate to the theta motor housing with three screws previously removed. 3. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). Note: Do not use the torque tool that came with the new encoder assembly for this task. 4. Place the theta coupling plate over the theta motor housing while you align the encoder shaft with the flex coupling. 5. Secure the theta encoder coupling plate to the theta motor housing using the four screws previously removed. 6. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). Note: Do not use the torque tool that came with the new encoder assembly for this task. 7. Using the Torx hex wrench shipped with the new encoder assembly, tighten the top set screw in the flex coupling to secure the coupling to the encoder coupling plate. 8. Store the Torx hex wrench back in the package in which it was shipped. 9. Connect the theta encoder cable connector P702 to the theta turns counter PMC card. 10. Restore the LSM; see Equipment Restoral Procedures in Chapter 7, Equipment Restoral Procedures.

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Figure 6-64. Theta Encoder Assembly (9310/L5510 Only)

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Theta Arm Assembly (4410 Only)


The procedure for removing and replacing the theta arm assembly involves removing the Z channel assembly and all components mounted on it, the REI card cage, theta drive assembly, an upper inner wall, and the cartridges located in that wall. The procedure involves other removal and replacement procedures to gain access to the theta arm assembly itself. These procedures are referenced and the steps involved in these procedures must be followed. After completing a procedure, return to the next step of this procedure to continue. WARNING: Lifting hazard: The 4410 theta arm assembly weighs approximately 180 lb (67.14 kg) and the theta drive assembly 16.785 kg (45 lb). Because of the weight of the theta drive and the awkward position for removing and replacing it, the theta drive assembly requires two persons to lift it. Three persons are required to lift the theta arm assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove both hands from the turntable; see the removal procedure in Hand Assembly without Camera (4410 Only) on page 6-170. 3. Remove the turntable assembly; see the removal procedure in Turntable Assembly (4410) on page 6-173. 4. Remove the Z channel assembly; see the removal procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218 or Z Channel Assembly (4410 BeltDriven) on page 6-223. 5. Remove the cartridges from inner upper Wall 12. This is the wall located above the inner door. 6. With a scribe, place a mark on the top and bottom of each side of upper inner Wall 12 for alignment reference when installing the wall. 7. Remove upper inner Wall 12 from the LSM. 8. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 9. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 10. Disconnect all cable connectors from the REI motherboard and coil cable support.

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11. Disconnect the coil cable at the lower end. 12. Position it out of the way. 13. Remove the theta stop assembly; see the removal procedure in Theta Stop Assembly (4410 Old Style) on page 6-88 or Theta Stop Assembly (4410 New Style) on page 6-91. 14. Remove the REI card cage assembly from the theta arm. The card cage is secured to the theta arm with two Torx screws. 15. Remove the theta drive assembly; see the removal procedure in Theta Drive Assembly (4410) on page 6-155. 16. Remove the Z flex cable assembly from the theta arm; see the removal procedure in Z Flex Cable Assembly (4410) on page 6-160. 17. Remove the calibration assembly from the theta arm assembly by removing three 6/32 X 3/4-in. Torx pan-head screws. 18. Install the lifting handles to the theta arm as shown in Figure 6-65 on page 7-153. 19. Remove the eight bolts with split-lock washers that attach the theta arm to the theta base. The theta arm is now free to be lifted and removed from the LSM. 20. Rotate the theta arm into the inner doorway. 21. Lift the theta arm, and move it out of the LSM.

Replacement
1. Attach the lifting handles to the theta arm (see Figure 6-65 on page 7-153). 2. Lift the theta arm, and move it through the inner doorway with the arm positioned toward the access door. 3. Align the pin on the spindle to the base, place the barrel of the arm into the theta base, and lower the theta arm. 4. Thread eight 3/8-16 x 1-1/2-in. socket-head cap bolts, each with a flat and lock washer, into the holes and tighten. 5. Attach the calibration assembly to the theta arm assembly with three 6/32 x 3/4-in. Torx pan-head screws. 6. Replace the theta drive assembly; see the replacement procedure in Theta Drive Assembly (4410) on page 6-157. 7. Replace the Z channel assembly; see the replacement procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-222 or Z Channel Assembly (4410 Belt-Driven) on page 6-228. 8. Replace the turntable; see the replacement procedure in Turntable Assembly (4410) on page 6-175.

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9. Replace the hands; see the replacement procedure in Hand Assembly without Camera (4410 Only) on page 6-172. 10. Replace the Z flex cable assembly; see the replacement procedure in Z Flex Cable Assembly (4410) on page 6-162. 11. Install the card cage assembly by positioning the card cage over the four alignment pins on the theta arm and securing with the two Torx screws. 12. Tighten the screws to a torque of 5 to 7 Nm (45 to 60 in.-lb). 13. Position the coil cord cable end beneath the clamp portion of the strain relief, thread the two Torx screws into the clamp and tighten. 14. Connect all cable connector plugs to their respective connector jacks on the REI motherboard, cable support bracket, and Z channel assembly. 15. Replace the theta stop assembly; see the replacement procedure in Theta Stop Assembly (4410 Old Style) on page 6-90 or Theta Stop Assembly (4410 New Style) on page 6-93. 16. Install upper inner Wall 12. Use the alignment marks scribed during the removal process when bolting the wall into place. 17. Close, align, and secure the inner door. Use the alignment marks to position the door. 18. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 19. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 20. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-65. Theta Arm Removal/Replacement

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Figure 6-66. Theta Drive Assembly (Sheet 1 of 2)

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Figure 6-67. Theta Drive Assembly (Sheet 2 of 2)

Theta Drive Assembly (4410)


WARNING: LIfting hazard: The theta drive assembly weighs 16.785 kg (45 lb). Because of the weight of the assembly and the awkward position for removing or installing it, two persons are required to prevent a possible lifting injury. See Figure 6-66 on page 6-154 and Figure 6-67 on page 6-155 and use the following procedures to remove and replace the theta drive assembly.

Removal
1. See LSM Entry Procedure on page xliv.

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2. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 3. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 4. Disconnect P705, P706, and P710 from the REI motherboard. 5. Disconnect BNC connectors P722-0 and P722-1 located below the theta coil cord support. a. Cut the two cable ties attaching the coil cord to the REI card cage support.

b. Remove the four screws attaching the theta coil card support, and remove the support. 6. Remove the breather vent from the center of the theta drive hub and replace with the 1/8-in. NPT pipe plug that has been stored with the shipping cover and lifting handle. 7. Keep the breather vent for installation on the new theta drive. 8. Remove the six nuts, split-lock washers, and flat washers from the center of the drive plate. 9. Remove the eight 1/4 - 20 x 0.625-in. Torx pan-head screws from the drive plate. 10. Pry up on the edge of the drive plate, and remove the plate from the theta arm. 11. Remove the eight 1/4 - 20 by 1 1/4-in. Torx pan-head screws from the drive assembly. 12. Remove six Torx screws from the automatic transmission fluid (ATF) shield. Leave the shield on. 13. Find the shipping cover from the original drive assembly. 14. Attach the shipping cover to the shield with the six nuts, split-lock washers, and flat washers you removed in Step 8. 15. Thread and tighten the six screws you removed in Step 12. Note: If the holes in the shipping plate do not align with the threaded holes in the harmonic drive housing, place a tool (such as an 8-in. crescent wrench) between the studs of the harmonic drive and turn until the holes align. 16. Disconnect the theta motor power cable P700 connector from J700 at the bottom of the theta base.

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17. From the top of the theta stop assembly, disconnect the encoder decode cable connector P702 from the MC card. 18. Open the replacement unit shipping container. 19. Lift the new drive assembly out of the container and lay it on its side. CAUTION: Encoder damage: Do not place it upright on the encoder mounted on the bottom of the drive assembly or remove the shipping plate until it is mounted in the theta housing. 20. Remove the two 3/8-16 by 1-1/4 in. socket-head screws and flat washers that attach the lifting handle. CAUTION: Fluid spillage: If there is no spare shipping plate to attach to the old assembly, keep the assembly vertical so automatic transmission fluid (ATF) does not spill from the top of the assembly. You can attach the shipping plate from the new assembly later. 21. Install the lifting handle onto the drive assembly being removed, threading the screws with flat washers into the holes and alternately turning the screws clockwise until the drive assembly is lifted out of the housing. 22. Lift the drive assembly up and out of the theta arm housing. Use care when lifting the drive assembly to avoid damaging the cables if they should become entangled. 23. Roll the blue ribbon theta encoder cable from the connector end and place the cable roll into the grommet in the theta encoder cover. 24. Place the old drive assembly in the shipping container.

Replacement
1. Remove the lifting handle from the drive assembly you removed, and install it onto the replacement drive assembly. CAUTION: Cable damage: Leave the blue ribbon cable inside the encoder cover grommet until the drive is seated to prevent damage to the cable. 2. Lift the drive assembly above the theta base and route the power cable and the lace from the encoder cable down through the center of the theta base. Route the lace from the encoder cable through the top hole in the side of the theta base. 3. Lower the drive assembly into place in the top of the theta arm. Maintain vertical orientation of the assembly to prevent binding. The motor cable and the lace should be held slightly taut while the assembly is being lowered.

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4. Align the holes in the drive assembly with the threaded holes and the dowel pin in the theta arm. 5. To properly seat the drive assembly (approximately last inch), insert three or four 1/4-20 x 1-1/2-in. screws equally spaced about the assembly screw circle. Tighten the screws alternately to seat the assembly evenly into the bore. When the screws bottom out, remove them. 6. Remove the lifting handle and store the handle and hardware in the Tool Kit. 7. Remove the six nuts, split lock washers, and flat washers from the center of the shipping plate. 8. Remove the six screws attaching the shipping cover to the ATF shield, remove the shipping cover, and put the cover into the Tool Kit. (If necessary, install it onto the drive assembly that was removed.) CAUTION: Component damage: If the O-ring seal has come out of the shipping plate and is on top of the harmonic drive, remove it and place it back with the shipping plate. The theta drive does not operate properly if the seal is left on top of the drive after the drive plate is installed. 9. Thread and tighten the six screws into the ATF shield. 10. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 11. Thread a 1/4-20 by 1 and 1/4-in. Torx pan-head screw into each of the eight holes in the theta base. 12. Using a star pattern (stagger torque), tighten the screws to a torque of 7.3 Nm (65 in.-lb). CAUTION: Drive plate check: If you are replacing an older version theta drive assembly (PN 410262605 or earlier), you must replace it with a theta drive assembly with drive plate FRU, PN 411099401, and use the new, required drive plate that comes as part of this FRU. If this FRU has already been installed, use the drive plate you removed earlier. 13. Install the drive plate onto the theta arm by placing the plate that connects the drive assembly to the theta arm on top of the drive/arm assembly. Align the six 3/8-16-in. studs and pin on the drive assembly with the holes in the drive plate. Rotate the theta arm until the holes in the drive plate are aligned with the threaded holes and pin in the theta arm assembly.

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14. Use the 3/8-in. nuts, split-lock washers, and flat washers to secure the drive plate to the drive assembly. 15. Tighten the nuts to a torque of 35 Nm (312 in.-lb). 16. Thread and tighten the eight 1/4-20 by 0.625-in. Torx pan-head screws securing the drive plate to the theta arm. 17. Tighten the screws to a torque of 6 Nm (53 in.-lb). 18. Remove the pipe plug from the top center of the theta drive. 19. Insert a clean blade of a 4-in. Phillips-head screwdriver into the hole where the plug was removed until the blade bottoms. 20. Remove the screwdriver and check for evidence of automatic transmission fluid (ATF) on the tip of the screwdriver. 21. If fluid is not visible on the screwdriver, slowly add a small amount of ATF and check again. Continue until ATF can be seen on the end of the blade. 22. Thread the previously removed breather vent into the theta drive and tighten securely. 23. Pull the lace through the top hole in the side of the theta base, pulling P702 and the encoder cable out of the theta encoder cover grommet. 24. Cut the lace attached to P702 and remove the lace from the connector. 25. Connect the encoder decode cable connector P702 to J702 through the top of the theta stop assembly and into the MC card behind the cover. 26. Connect the theta power cable P700 connector to the cable connector J700 at the bottom of the theta base. 27. Install the theta coil cord support with the four screws. a. Attach the theta coil cord to the coil card support with new cable ties.

b. Connect BNC connectors P722-0 and P722-1 below the theta coil cord support. c. Connect P705, P706, and P710 to the REI motherboard.

28. Attach and connect the coil cord cable to REI cable support and motherboard; see the replacement procedure for the theta coil cord cable. 29. Close, align, and secure the inner door. Use the alignment marks to position the door. 30. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 31. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 32. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Flex Cable Assembly (4410)


See Figure 6-68 on page 6-161 and use the following procedures to remove and replace the Z flex cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). 4. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 5. Disconnect P711, P712, P713, P714, and P715 from the REI motherboard. 6. Disconnect coaxial cable connectors P722-0 and P722-1 from the theta coil cord support. 7. Disconnect the five cable connectors J731 through J735 and two coaxial cable BNC connectors P736-0 and P736-1 from the cable bracket attached to the Z plate (leadscrew-driven) or Z arm (belt-driven). 8. Open the cable clamps to release the cables from the theta arm. 9. Remove the two Torx screws attaching the flat cable clamp bracket to the Z channel assembly. 10. Remove the three Torx screws securing the cable bracket to the back of the Z plate (leadscrew-driven) or Z arm (belt-driven). Ensure that the five Z flat flex cables and two coaxial cables are free for removal as an assembly.

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Figure 6-68. Z Cable Assembly

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Replacement
1. Align the cable bracket holes with those in the Z plate (leadscrew-driven) or Z arm (belt-driven), and thread and tighten the screws into the bracket. 2. Attach the flat cable clamp bracket to the Z channel assembly with two Torx screws. 3. Connect the five flex and two coaxial connectors to the bracket connectors. The cable from the MB card connects to the connector nearest the MB card. 4. Verify that labels on the cables match labels on the connectors (such as P735 goes into J735). 5. Route the Z flex cable assembly through the six cable clamps on the theta arm and secure within the clamps. 6. Connect the Z flex cable assembly connectors to their respective motherboard connectors and the coaxial connectors to the theta coil cord cable support bracket. 7. Verify that Coaxial Cable 0 and Coaxial Cable 1 connect to the properly labeled connector. 8. Move the Z arm from limit to limit slowly, making sure that there is no strain on the cables. 9. Close, align, and secure the inner door. Use the alignment marks to position the door. 10. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 11. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Motor/Encoder Assembly (4410 Leadscrew-Driven)


See Figure 6-69 on page 6-164 and use the following procedures to remove and replace the Z motor/encoder assembly on the leadscrew-driven Z channel.

Removal
1. See LSM Entry Procedure on page xliv. 2. Disconnect P725 and P726 from their respective connectors. 3. Remove the cables from any cable clamps. 4. Loosen the four Torx screws in the motor plate. 5. Grasp the top of the motor, and rotate it enough to free and remove the belt. 6. Remove the belt tension spring from the motor plate. 7. Support the motor and remove the four Torx screws securing the motor plate to the Z channel top plate. 8. Loosen the allen-head screw in the pulley collar, and slide the belt pulley off the motor shaft. 9. Remove the four Torx screws securing the motor to the mounting plate, noting the cable orientation.

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Figure 6-69. Z Motor/Encoder Assembly (Leadscrew-Driven)

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Replacement
1. Attach the motor to the mounting plate with four Torx screws, noting the cable orientation. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Attach the belt pulley to the motor shaft, and install the collar over the split sleeve on the pulley. Note: Do not tighten the allen-head screw in the collar until the pulley is aligned with the Z leadscrew pulley. 4. Attach the motor plate to the Z channel top plate loosely using four Torx screws. 5. Attach the belt tension spring to the motor plate. 6. Rotate the motor assembly counterclockwise, and place the belt over the motor pulley. Release the motor, and tighten the four Torx screws to secure the motor plate to the Z channel top plate. 7. Place a 12-in. steel ruler across the motor and leadscrew pulleys. Adjust the motor pulley on the shaft until the two pulleys are properly aligned with each other. 8. Tighten the allen-head screw in the motor pulley collar. 9. Re-tension the belt by loosening the four screws. 10. Tighten the screws to a torque of 3 Nm (26 in.-lb). 11. Connect P725 and P726 to their respective connectors. 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Motor/Encoder Assembly (4410 Belt-Driven)


See Figure 6-70 on page 6-167 and use the following procedures to remove and replace the Z motor/encoder assembly on the belt-driven Z channel.

Removal
1. See LSM Entry Procedure on page xliv. 2. Disconnect P725 and P726 from their respective connectors, and free the cable from the clamp above P725. 3. Free the cables from the two cable clamps on the top plate assembly. 4. Loosen the two machine screws in the outer coupling attached to the Z motor/encoder shaft. 5. Support the Z motor/encoder, and remove the four screws from the bottom side of the top plate that attach the Z motor bracket to the top plate. 6. Slide the coupling off the Z motor shaft. 7. Remove the four screws attaching the Z motor/encoder to the Z motor bracket.

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Figure 6-70. Z Motor/Encoder Assembly (Belt-Driven)

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Replacement
1. Attach the Z motor/encoder to the Z motor bracket using the four 10-32 x 3/4-in. screws previously removed. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Slide the outer coupling onto the Z motor shaft with the slot positioned away from the motor. Do not tighten the screws. 4. Attach the Z motor bracket to the top plate using the four 10-32 x 3/4-in. screws previously removed. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Place the middle coupling between the two outer couplings and mate the surfaces. 7. Slide the coupling on the Z motor/encoder side toward the other outer coupling until all three couplings are fully mated. 8. Tighten the two machine screws in the outer coupling. Note: If both outer couplings have been untightened and moved on the two shafts, position the outer coupling on the belt pulley shaft 6.3 mm (0.25 in.) from the belt pulley bracket, tighten the screws, and perform the two previous steps. 9. Secure the two cables into the two cable clamps on top of the top plate assembly, and secure the cable into the clamp above J725. 10. Connect cable connectors J725 and J726 to their respective cable connectors on the Z channel. 11. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Camera Assembly with Mounting Plate (4410 Only)


See Figure 6-71 on page 6-171 and use the following procedures to remove and replace the camera assembly with mounting plate.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Pull the camera power cable back on the collar of P786 to release. 4. Remove the camera signal cable P785. 5. Remove four #4 Torx screws securing the camera plate to the camera mount. Retain the two cable clamps held on by two of those screws and lift the camera off the dowel pins on the camera mount.

Replacement
1. Place the camera onto the camera mount dowel pins and attach the camera and two cable clamps with four #4 Torx screws. 2. Tighten the screws to a torque of 0.6 Nm (5 in.-lb). 3. Remove the lens cap from the camera, and place it onto the camera being returned. 4. Connect P785 and P786 to the camera assembly. 5. Remove and reseat camera lamps on both hands. Ensure a firm lamp connection with the lamp socket exists. 6. Remove the locking pin(s) from the Z channel assembly and move the Z arm from limit to limit to check for unrestricted movement. 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-71. Camera Assembly

Hand Assembly without Camera (4410 Only)


See Figure 6-72 on page 6-171 and use the following steps to remove and replace either hand assembly on the turntable.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Disconnect P756, P759, P760, P761, and P782 from the hand assembly.

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Figure 6-72. Hand Assembly

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4. Remove the camera; see the removal procedure in Camera Assembly with Mounting Plate (4410 Only) on page 6-169. 5. Remove the two screws securing the hand to the turntable from the bottom of the hand.

Replacement
1. Position the hand assembly to align the hand with the alignment pin on the turntable. 2. Thread and tighten the two screws from beneath the turntable to secure the hand in place. 3. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Connect P756, P759, P760, P761, and P782. CAUTION: Cable damage: Connect cable connector P760 after P759 is connected. Route the P760 cable behind P759 to prevent the cable from coming in contact with the turntable belt. On older style MS cards, the cable might require rotation to prevent contact with the roll belt. 5. Remove the Velcro strap from each side of the hand. The strap isolated the reach mechanism from movement during shipment. 6. Remove the #6 Torx screw from the top (12 oclock position) of the hand. This screw isolated the roll mechanism from movement during shipment. 7. Replace the camera; see the replacement procedure in Camera Assembly with Mounting Plate (4410 Only) on page 6-169. 8. Remove and reseat both camera lamps on both hands. Ensure a firm lamp connection with the lamp socket exists. 9. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 10. Attach the Velcro strap to each side of the hand being returned, isolating the reach mechanism from movement during shipment 11. Thread and tighten the #6 Torx screw into the top (12 oclock position) of the hand, isolating the roll mechanism from movement during shipment. 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Hand Front Plate Bearing Kit (4410)


See the removal and replacement procedures in Gripper Assembly (4410 Only) on page 6-105 to remove and replace the Hand Front Plate Bearing Kit.

Turntable Assembly (4410)


See Figure 6-73 on page 6-174 and Figure 6-74 on page 6-175 and use the following procedures to remove and replace the 4410 turntable on the Z arm.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Remove the two hand assemblies. 4. Disconnect P782-0 and P782-1 coaxial BNC connectors from the turntable. 5. Remove the two cable clamps securing the coaxial cables to the coaxial cable brackets. These clamps were added on the newer version turntable assemblies. 6. Remove the two cable clamps securing Coaxial Cable 1 to the turntable. 7. Disconnect P750, P751, P752, and P753 flex cable connectors from the MS card. 8. Remove the two Torx screws securing the cable bracket to the turntable. Let the cable assembly hang. 9. Remove the Torx screw securing the turntable to the turntable shaft. 10. Loosen the four Torx screws in the turntable motor plate. 11. Twist the motor assembly counterclockwise, and remove the belt from the turntable pulley. 12. Lift the turntable off the shaft.

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Figure 6-73. Turntable Assembly, 4410 (Sheet 1 of 2)

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Figure 6-74. Turntable Assembly, 4410 (Sheet 2 of 2)

Replacement
1. Lay the belt over the Z arm. 2. Place the turntable onto the shaft. The turntable sensor flag should face away from the Z channel assembly. 3. Thread and tighten the Torx screw securing the turntable to the shaft. 4. Tighten the screw to a torque of 3 Nm (26 in.-lb). Note: While the turntable is removed, replace the turntable belt if it has not been replaced in the past 60 days.

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5. Twist the turntable motor sufficiently to place the belt around the pulley. 6. Release the motor, and tighten the four Torx screws to secure the motor. The spring provides the proper belt tension. 7. Attach the cable bracket to the turntable with two Torx screws. 8. Connect P782-0 and P782-1 coaxial BNC connectors to the turntable. 9. Attach the three cable clamps to P782-1 coaxial cables and the clamp to P782-0 coaxial cables. 10. Secure the cables to the turntable and the coaxial cable brackets with the four screws. 11. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 12. Connect flex cable connectors P750, P751, P752, and P753 to the cable bracket. 13. See Camera Assembly with Mounting Plate (4410 Only) on page 6-169 for installing both cameras. 14. Remove the locking pin(s) from the Z channel assembly and move the Z arm from limit to limit to check for unrestricted movement. 15. See Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Turntable Assembly (9310/L5510 Only, Din Connector)


See Figure 6-75 on page 6-177 and use the following procedures to remove and replace the turntable assembly when the Z transport has the Din connector.

Removal
1. See LSM Entry Procedure on page xliv. 2. Position the turntable at approximately waist height at the LSM doorway. 3. Rotate the transport wrist clockwise to position the hand to the inner wall, giving you the best access to the connector. 4. Disconnect the transport flex assembly connector from the turntable: a. Slide the flex cable bracket off the lower pins.

b. Unscrew the panel fastener on the transport flex assembly. c. Unplug the transport flex assembly from the turntable assembly.

5. Remove and retain the screw that attaches the turntable to the Z transport assembly. 6. Lift the turntable off the transport.

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Figure 6-75. Turntable Assembly (9310/L5510 Only, Din Connector)

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Replacement
CAUTION: EQUIPMENT DAMAGE. To avoid damage to the robot and other LSM components, you must mount a 9310 turntable if the LSM is a 9310, or you must mount an L5510 turntable if the LSM is an L5510. DO NOT INSTALL AN L5510 TURNTABLE ASSEMBLY ON A 9310 LSM, OR VICE VERSA. SEE Figure 6-76 AND Figure 6-77 on page -179 TO IDENTIFY THE DIFFERENCES BETWEEN THE ASSEMBLIES. Figure 6-76. L5510 Turntable Assembly

C29913

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Figure 6-77. 9310 Turntable Assembly

C29914

1. Install the turntable assembly onto the transport, and attach it with one screw. 2. Verify that the locating hub on the transport matches up correctly and completely with the locating hub on the bottom of the turntable. 3. Tighten the screw to a torque of 3 Nm (26 in.-lb). 4. Rotate the transport wrist clockwise to position the hand to the inner wall, giving you the best access to the connector. 5. Plug the transport flex assembly into the turntable connector. a. Grasp the end of the transport flex connector, and plug it into the connector on the turntable assembly.

b. Make sure that the connector is firmly seated. c. Screw the panel fastener on the transport flex into the standoff on the turntable assembly.

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d. Tighten the screw to a torque of 0.95 Nm (8 in.-lb). e. f. Slide the flex cable bracket on the lower pins of the turntable assembly. Make sure that the bracket is fully engaged and locked in place.

6. See Library Storage Module Restoral on page 2

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Turntable/Z Transport Assembly


Use Table 6-1, Figure 6-78 on page 6-183 through Figure 6-81 on page -186 on page 6-186, and the following procedures to remove and replace the turntable assembly and Z transport assembly when your transport flex assembly has the Invisicon connector. The new assemblies in the replacement procedure contain the DIN connector. Table 6-1. Turntable/Z Transport Assembly Parts Guide Present part to be replaced . . . Turntable assembly 308469208 Turntable assembly 308469208 or lower Z transport assembly 3084974xx Z transport assembly 308469306 or lower Z transport assembly 308469307 or higher Transport flex assembly 3084165xx Transport flex assembly 3084575xx And these parts presently in LSM . . . Transport flex assembly 3084165xx Transport flex assembly 3084575xx Turntable assembly 308469209 or higher Required parts Turntable/transport 4112959xx Turntable assembly 3084692xx Turntable assembly 3084692xx Turntable/transport 4112959xx Z transport assembly 3084693xx Turntable/transport 4112959xx Turntable assembly 3084692xx Transport flex 3084974xx Transport flex 3084974xx

Transport flex assembly 3084974xx

Turntable Assembly Removal


1. See LSM Entry Procedure on page xliv. 2. Position the turntable at approximately waist height at the LSM doorway. 3. Rotate the transport wrist clockwise to position the hand to the inner wall, giving you best access to the connector. 4. Disconnect the transport flex assembly connector from the turntable. a. Slide the flex bracket off the lower pins.

b. Lift the flex backshell connector off the upper pins, freeing the transport flex from the turntable assembly. c. Raise the transport to the top of the Z column.

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d. Remove and retain the screw that attaches the turntable to the Z transport assembly. 5. Lift the turntable assembly off the transport, and set it aside.

Z Transport Removal
CAUTION: Component damage: The Z flex guide is very fragile. Any kink or bend introduced during handling will greatly reduce the life of the guide and damage or destroy the Z flex circuit. 1. Remove the screw that attaches the Z flex guide to the Z flex support bracket. 2. Remove the four screws that attach the Z flex circuit to the transport. 3. Disconnect the Z flex circuit connector. CAUTION: Secure Z belt: Do not allow the belt to fall into the Z column, or you will have to remove the Z column and dismantle it to retrieve the belt. 4. Remove the screw that secures the belt clamp to the Z transport assembly. 5. Hold the transport and pull down on the belt to free the belt and belt clamp. 6. While holding the belt, lower the transport to the bottom of the Z column. 7. Lower the counterweight into the Z column, and secure the belt to the Z column cap assembly. 8. Remove the screws that attach the two roller assemblies to the transport (adjacent to the Z flex support bracket), and remove the assemblies. 9. Remove the transport from the Z column. 10. Attach the two roller assemblies to the transport.

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Figure 6-78. Turntable/Z Transport Assembly Removal (Sheet 1 of 4)

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Figure 6-79. Turntable/Z Transport Assembly Removal and Replacement (Sheet 2 of 4)

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Figure 6-80. Turntable/Z Transport Assembly Removal and Replacement (Sheet 3 of 4)

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Figure 6-81. Turntable/Z Transport Assembly Replacement (Sheet 4 of 4)

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Z Transport Replacement
CAUTION: Component damage: The Z flex guide is very fragile. Any kink or bend introduced during handling will greatly reduce the life of the guide and damage or destroy the Z flex circuit. 1. Locate the new Z transport assembly. 2. Remove the two roller assemblies. 3. Position the transport onto the Z column and attach the roller assemblies to the transport. 4. Tighten the two screws to a torque of 3 Nm (26 in.-lb). 5. Place the belt through the transport, align the last belt tooth with the last groove in the belt clamp, and secure with a screw. 6. Tighten the screw to a torque of 3 Nm (26 in.-lb). 7. Connect the Z flex circuit connector to the transport and secure to the Z flex support bracket using the four screws previously removed. 8. Tighten the screws to a torque of 3 Nm (26 in.-lb). 9. Attach the Z flex guide to the Z flex support bracket on the transport using the screw previously removed. 10. Tighten the screw to a torque of 3 Nm (26 in.-lb). 11. Check for unrestricted movement of the transport assembly from limit to limit.

Turntable Replacement
1. Locate the new turntable assembly. 2. Install the turntable assembly onto the transport and attach with the screw previously removed. 3. Verify that the locating hub on the transport matches up correctly and completely with the locating hub on the bottom of the turntable. 4. Tighten the screw to a torque of 3 Nm (26 in.-lb).

Transport Flex Attachment


1. Rotate the transport wrist clockwise to position the hand to the inner wall, giving you best access to the connector. 2. Grasp the ends of the connector on the transport flex, and plug them into the connector on the turntable assembly. 3. Make sure that the connector is fully seated.

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4. Screw the panel fastener on the transport flex into the standoff on the turntable assembly. 5. Tighten the screw to a torque of 0.95 Nm (8 in.-lb). 6. Slide the flex cable bracket on the lower pins of the turntable assembly, making sure that the bracket is fully engaged and locked in place. 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Camera W/Bracket (9310/L5510 Only)


See Figure 6-82 on page 6-189 and use the following procedures to remove and replace the 9310/L5510 camera.

Removal
1. See LSM Entry Procedure on page xliv. 2. Position the turntable at approximately waist height. 3. Remove and retain the 4-40 x 0.5-in. Torx pan-head screws that attach the hand flex assembly connector to the connector on the camera. 4. Pull the connector from the camera. 5. Remove and retain the two 6-32 x 1/4-in. or 6-32 x 1-1/2-in. Torx pan-head screws that attach the camera to the hand assembly and remove the camera.

Replacement
1. Align the camera mounting bracket with the hand assembly threaded holes, and attach the camera using the two screws supplied with the camera. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect the hand flex connector to the camera and secure it with the two screws you previously removed. 4. Remove the camera lens cover, and attach to the camera that was removed. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-82. Camera and PLE (9310/L5510 Only)

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PLE Card (9310/L5510 LED Lamps)


See Figure 6-82 on page 6-189 and use the following procedures to remove and replace the 9310/L5510 PLE card.

Removal
1. See LSM Entry Procedure on page xliv. 2. Using a common-blade screwdriver, gently pry one end of the PLE card off the plastic split posts that secure the card to the hand assembly shell. 3. Pry the other end off the split post, and remove the PLE from the connector pins on the hand flex.

Replacement
1. Align the PLE card connector with the hand flex connector pins and plastic split posts on the hand assembly shell. CAUTION: Component damage: Do not press on the LEDS, as they could be misaligned. The PLE card must be fully seated to prevent vision errors. 2. Using the green circuit card portion, press the PLE card down onto the three split posts until it is firmly seated. Listen for the snap over all three split posts. 3. Push down firmly on two opposite corners of the card simultaneously to make sure that the card is not tilted. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Turntable Motor/Encoder (4410)


See Figure 6-83 on page 6-191 and use the following procedures to remove and replace the turntable motor/encoder assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Disconnect P741 and P742 from the MB card. 4. Loosen four Torx screws in the turntable motor plate. 5. Grasp the motor and turn it counterclockwise to remove the tension from the turntable cog belt.

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6. Remove the belt from the turntable motor pulley. 7. From beneath the turntable motor bracket, remove the three Torx screws that attach the turntable motor/encoder assembly to the turntable motor plate. 8. Loosen the screw in the collar clamp on the motor pulley. 9. Remove the motor pulley from the motor. Figure 6-83. Turntable Motor/Encoder Assembly

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Replacement
1. Install and seat the motor pulley/collar clamp on the motor shaft. 2. Tighten the screw in the collar clamp. 3. Mount the turntable motor/encoder assembly on top of the turntable motor plate using the three Torx screws. 4. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). Note: Position the motor/encoder leads so they reach the connectors on the MB card. 5. Grasp the motor, and turn it counterclockwise to allow the belt to attach to the motor pulley. 6. Ensure the belt is over both the motor and turntable pulleys. 7. Tighten the four screws securing the turntable motor/encoder assembly to the turntable motor plate. 8. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 9. Connect P741 and P742 to the designated MB card connectors. 10. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 11. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Turntable Bearing Assembly (4410)


See Figure 6-84 on page 6-193 and use the following procedures to remove and replace the turntable bearing assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Remove the hands; see the removal procedure in Hand Assembly without Camera (4410 Only) on page 6-170. 4. Remove the turntable; see the removal procedure in Turntable Assembly (4410) on page 6-173. 5. Scribe alignment marks on the turntable sensor plate assembly and Z arm to use as a reference when replacing.

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Figure 6-84. Turntable Bearing Assembly

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6. Disconnect the two sensor connectors J1 from the turntable sensor cable connectors P1 CW and P1 CCW. 7. Remove the four Torx screws from the turntable sensor plate assembly. 8. Lift off the bearing assembly and sensor plate.

Replacement
1. Place turntable bearing assembly onto the Z arm. 2. Position the sensor plate over the assembly. 3. Align the scribed marks on the Z arm and bearing/sensor plate, pushing the edge of the sensor plate flush against the Z arm. 4. Thread and tighten the screws securing the plate to the arm. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Connect the two sensor cables J1 to the turntable sensor cable connectors P1 CW and P1 CCW. 7. Replace the turntable; see the replacement procedure in Turntable Assembly (4410) on page 7-175. 8. Replace the hands; see the replacement procedure in Hand Assembly without Camera (4410 Only) on page 6-172. 9. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Column Assembly (9310/L5510 Only)


See Figure 6-85 on page 6-196 and Figure 6-86 on page 6-197 and perform the following procedures to remove and replace the Z column assembly.

Removal
1. See LSM Entry Procedure on page xliv. CAUTION: Component damage: The Z flex guide is very fragile. Any kink or bend introduced during handling will greatly reduce the life of the guide and damage or destroy the Z flex circuit. 2. Remove the screw attaching the Z flex guide to the Z flex support bracket on the Z transport assembly. Support the Z flex guide on the theta arm. 3. Remove the four screws attaching the Z flex to the Z flex support bracket on the Z transport assembly. 4. Support the Z flex on the theta arm. 5. Disconnect the Z motor power cable connector P720 from the motor cable connector J720. 6. Disconnect the Z motor encoder cable connector P725 from the Z motor flex at the Z column top cap. 7. Free the Z motor power and encoder cables from the cable raceway on the back of the Z column. Rest the cables across the theta arm. 8. Remove the turntable assembly from the Z transport; see Turntable Assembly (9310/L5510 Only, Din Connector) on page 6-176. 9. Remove the eight screws attaching the Z column to the theta to Z transition bracket. 10. Lift the Z column up to align the keyhole slot and pin, and remove the Z column from the theta arm.

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Figure 6-85. Z Column Assembly (9310/L5510 Only) (Sheet 1 of 2)

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Figure 6-86. Z Column Assembly (9310/L5510) (Sheet 2 of 2)

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Replacement
1. Lift the Z column and align the keyhole with the pin on the theta to Z transition bracket. 2. Secure the Z column to the theta to Z transition bracket using the eight screws previously removed. 3. Tighten the screws to a torque of 5 to 7 Nm (45 to 60 in.-lb). 4. Unscrew the bolt from the center of the counterweight that secures the counterweight to the bottom of the Z column, and remove the attaching device. 5. Attach the device to the removed Z column to secure the counterweight at the bottom of the Z column for shipment. 6. Attach the turntable assembly to the Z transport; see the turntable replacement procedure in Turntable Assembly (9310/L5510 Only, Din Connector) on page 6-178. 7. Route the Z motor power and encoder cables through the cable raceway on the back of the Z column. 8. Connect the Z motor encoder cable connector P725 to the Z motor flex at the Z column top cap. 9. Connect the Z motor power cable connector P720 to the motor cable connector J720. 10. Attach the Z flex to the Z flex support bracket on the Z transport assembly using the four screws previously removed. 11. Attach the Z flex guide to the Z flex support bracket on the Z transport assembly using the screw previously removed. 12. Tighten the screw to a torque of 1.4 Nm (12 in.-lb). 13. Move the Z transport from limit to limit, and check for unobstructed movement. 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Motor Assembly (9310/L5510 Only)


See Figure 6-87 on page 6-200 and use the following procedures to remove and replace the Z motor assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two screws attaching the Z motor flex to the Z motor encoder. Retain the screws for reattaching the flex to the new motor. 3. Disconnect the Z motor flex from the encoder. 4. Remove the Z motor power cable connector J720 by squeezing the ears of the connector inward and withdrawing the connector from the Z column cap assembly. 5. Cut and remove the tie wrap securing the Z motor cable to the Z column cap assembly. 6. Remove the lower two screws attaching the Z motor to the Z column cap. 7. Pull the counterweight belt up, and remove it from the Z motor pulley. 8. Remove the Z motor assembly from the Z column cap assembly by removing top two screws while supporting the motor. Retain the screws for attaching the new motor.

Replacement
1. Attach the Z motor assembly to the Z column cap assembly using the four screws previously removed. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Lift the counterweight belt up, and place the belt over the motor pulley. 4. Attach the Z motor power cable connector J720 to the Z column cap assembly by pushing the end of the connector into the connector cutout until the ears of the connector lock into place. 5. Secure the Z motor cable to the hole in the Z column cap assembly with a cable wrap. 6. Connect the Z motor flex to the Z motor encoder. 7. Secure the Z motor flex to the encoder using the two screws previously removed. 8. Tighten the screws to a torque of 0.95 Nm (8 in.-lb). 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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/L5510

Figure 6-87. Z Motor and Flex (9310/L5510 Only)

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Z Motor Flex (9310/L5510 Only)


See Figure 6-87 on page 6-200 and use the following procedures to remove and replace the Z motor flex.

Removal
1. See LSM Entry Procedure on page xliv. 2. Disconnect the Z motor encoder cable assembly connector from the Z motor flex connector. 3. Remove the three screws attaching the Z motor flex to the Z column cap. 4. Remove the two screws attaching the Z motor flex to the Z motor encoder, and disconnect and remove the flex.

Replacement
1. Connect the Z motor flex to the Z motor encoder and attach using the two screws previously removed. 2. Tighten the screws to a torque of 0.95 Nm (8 in.-lb). 3. Attach the Z motor flex to the Z column cap using the three screws previously removed. 4. Tighten the screws to a torque of 0.95 Nm (8 in.-lb). 5. Connect the Z motor encoder cable assembly (P725) to the Z motor flex. 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Transport Assembly (9310/L5510 Only)


Note: Carefully review the compatibility pages and Table 6-2 before replacing the Z transport assembly. You might also need to replace the turntable assembly due to changes made on the connector between the turntable and the transport and to earlier changes on the transport flex. Table 6-2. Z Transport Assembly (9310/L5510 Only) Parts Guide Present part to be replaced . . . Turntable assembly 308469306 or lower Turntable assembly 308469307 or higher Turntable assembly 308469208 or lower Turntable assembly 308469208 or lower Transport flex assembly 3084165xx Transport flex assembly 3084575xx And these parts presently in LSM . . . Required parts Turntable/transport 4112959xx Z transport assembly 3084693xx Turntable/transport 4112959xx Turntable assembly 3084692xx Z transport flex 3084974xx Turntable assembly 3084692xx Turntable/transport 4112959xx Turntable assembly 3084692xx

Turntable assembly 308469209 or higher Transport flex assembly 3084165xx Transport flex assembly 3084575xx Transport flex 3084974xx Transport flex assembly 3084974xx

Transport flex 3084974xx

See Figure 6-88 on page 6-204 and Figure 6-89 on page 6-205 and use the following procedures to remove and replace the Z transport assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Position the transport at approximately waist height. CAUTION: Component damage: The Z flex guide is very fragile. Any kink or bend introduced during handling will greatly reduce the life of the guide and damage or destroy the Z flex circuit.

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3. Remove the screw attaching the Z flex guide to the Z flex support bracket. 4. Remove the four screws, and disconnect the Z flex circuit from the Z flex support bracket. 5. Remove the turntable assembly; see the removal procedure in Turntable Assembly (9310/L5510 Only, Din Connector) on page 6-176. CAUTION: Secure the belt: Do not allow the belt to fall into the Z column, or you will have to remove the Z column and dismantle it to retrieve the belt. 6. Remove the screw securing the belt clamp to the transport. 7. Hold the transport and pull down on the belt to free the belt/belt clamp. 8. Lower the counterweight into the Z column, and secure the belt to the Z column cap assembly. Do not allow the belt to fall into the Z column. 9. Remove the screws attaching the two roller assemblies to the transport (adjacent to the Z flex support bracket). 10. Attach the two roller assemblies to the transport after the transport is removed from the Z column.

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/L5510

Figure 6-88. Z Transport Assembly (9310/L5510 Only) (Sheet 1 of 2)

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Figure 6-89. Z Transport Assembly (9310/L5510 Only) (Sheet 2 of 2)

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Replacement
1. Remove the two roller assemblies from the new transport assembly. 2. Position the new transport onto the Z column, and attach the roller assemblies to the transport. 3. Tighten the two screws to a torque of 3 Nm (26 in.-lb). 4. Place the belt through the transport, align the last belt cog with the last groove in the belt clamp and secure with screw. 5. Tighten the screw to a torque of 3 Nm (26 in.-lb). 6. Install the turntable assembly onto the transport, and attach with the screw previously removed. 7. Tighten the screw to a torque of 3 Nm (26 in.-lb). 8. Connect the transport flex to the turntable; see the replacement procedure in Z Motor Flex (9310/L5510 Only) on page 6-201. 9. Connect the Z flex circuit connector to the transport, and secure to the Z flex support bracket using the four screws previously removed. 10. Tighten the screws to a torque of 3 Nm (26 in.-lb). 11. Attach the Z flex guide to the Z flex support bracket on the transport using the screw previously removed. 12. Tighten the screw to a torque of 3 Nm (26 in.-lb). 13. Check for unrestricted movement of the transport assembly from limit to limit. 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Belt (9310/L5510 Only)


To remove the Z-belt from the Z column assembly, the turntable and Z column must first be removed from the theta arm. See Figure 6-90 on page 6-208 and use the following procedures to remove and replace the Z belt.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the Z column assembly from the transport; see the removal procedure in Z Column Assembly (9310/L5510 Only) on page 6-195. 3. Transport the Z column to a suitable work surface. WARNING: Bodily injury: Place the Z column on a workbench with the top of the column slightly higher than the bottom. Doing this prevents the counterweight from rolling out of the Z column unexpectedly and causing an injury when the cap assembly is removed from the Z column. 4. Remove the six screws attaching the cap assembly to the Z column. 5. Remove the screw attaching the Z transport belt clamp, and remove the belt end. 6. Remove the cap assembly from the Z column. 7. Remove the counterweight from the Z column by pulling on the belt. If the belt is inside the Z column, gently lower the Z column slightly to allow the counterweight to roll toward the top of the Z column. 8. Remove the Z belt clamp screw attaching the belt to the counterweight.

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Figure 6-90. Z Belt (9310/L5510 Only)

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Replacement
1. Position the new belt onto the counterweight belt clamp with the last belt cog aligned with the bottom groove of the clamp. 2. Insert the belt and clamp into the counterweight, and attach with the screw previously removed. 3. Tighten the screw to a torque of 3 Nm (26 in.-lb). 4. Slide the counterweight into the Z column, observing proper orientation. 5. Feed the belt through the bottom of the Z column cap assembly and across the idler pulley. 6. Insert the cap assembly into the top of the Z column, and secure with the six screws previously removed. 7. Tighten the screws to a torque of 5 Nm (45 in.-lb). 8. Route the belt across the Z motor pulley and down through the belt clamp opening of the transport. 9. Position the last cog of the belt onto the bottom groove of the belt clamp, and attach the belt and clamp to the transport with the screw previously removed. 10. Tighten the screw to a torque of 5 Nm (45 in.-lb). 11. Install the Z column assembly to the theta arm; see the replacement procedure in Z Column Assembly (9310/L5510 Only) on page 6-198. 12. Perform the procedure in Z Channel-to-Z Channel Alignment and, if necessary, the procedure in Z Channel Re-tightening Procedure on page 6-210. 13. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Z Channel-to-Z Channel Alignment


See Figure 6-91 on page 6-211 through Figure 6-93 on page 6-213. 1. Attach the wall alignment tool to Turntable 0. Note: The lines of the alignment tool are 1/8-in. apart. Therefore, 1/16-in. must be estimated as halfway between two lines. 2. Check the distance to the following two targets on Wall 10 (the CD wall). Row 1, Column 10 Row 14, Column 10

3. Measure to the bottom corner of the target as shown in the illustrations. Record the measurements in Table 6-3 on page 6-210.

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4. Attach the wall alignment tool to Turntable 1. 5. Check the distance to the following two targets on Wall 10 (the CD wall). Row 1, Column 10 Row 14, Column 10

6. Measure to the bottom corner of the target as shown in the illustrations. Record the measurements Table 6-3. Table 6-3. Turntable Measurements Row 1 Turntable0 Turntable2 Difference 7. If the differences between the top and bottom measurements are 1/16-in. or less, the Z column parallelism is satisfactory. Do not perform the procedure in Z Channel Re-tightening Procedure. If the differences between the top and bottom measurements are more than 1/16-in., perform the procedure in Z Channel Re-tightening Procedure. Row 14

Z Channel Re-tightening Procedure


See Figure 6-93 on page 6-213. 1. Position the Z transport to the bottom of the Z channel to provide easy access to the hardware without any damage to the flex circuit and guide. 2. Loosen all eight screws attaching the Z column to the theta arm transition bracket. Note: Do not remove the Z column. 3. Tighten all eight screws to a torque of 0.6 Nm (5 in.-lb). 4. Make sure that the Z channel can still move. 5. Tighten the rear four screws (the screws toward the center of the library) to a torque of 7 Nm (60 in.-lb); tighten them in an X-pattern; that is, top-left, bottom-right, top-right, and bottom-left. 6. Tighten the remaining four screws to a torque of 7 Nm (60 in.-lb). 7. Repeat Steps 1 through 6 for the other Z channel. 8. Verify the parallelism of the Z channels using the procedure in Z Channel-to-Z Channel Alignment on page 6-209. 9. If the difference between the measurements is still not 1/16-in. or less, open a Sev 4 incident in FIXIT, ADD KEYWORD ZALIGN & FB52709.

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Figure 6-91. Z-to-Z Channel Check1

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Figure 6-92. Z-to-Z Channel Check2

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Figure 6-93. Z to Z Channel Alignment

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Transport Flex Assembly (9310/L5510 Only)


Note: Carefully review the compatibility pages and Table 6-4 before replacing the transport flex assembly. You might also need to replace the transport assembly and the turntable assembly due to changes made on the connector between the turntable and the transport and to earlier changes on the transport flex. Table 6-4. Transport Flex Assembly (9310/L5510 Only) Parts Guide Present part to be replaced . . . Transport flex assembly 3084165xx Transport flex assembly 3084575xx Transport flex 3084974xx Transport flex 3084974xx Turntable assembly 308469208 or lower Turntable assembly 308469208 or lower Z transport flex 3084974xx Turntable assembly 308469209 or higher Z transport assembly 308469306 or lower Z transport assembly 308469307 or higher Turntable assembly 3084692xx Turntable/transport 4112959xx Z transport assembly 3084693xx Transport flex assembly 3084165xx Transport flex assembly 3084575xx Transport flex 3084974xx Turntable/transport 4112959xx Turntable assembly 3084692xx And these parts presently in LSM . . . Required parts Turntable/transport 4112959xx Turntable assembly 3084692xx

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Lower the transport assembly until you can work on it easily. 4. Remove the turntable assembly; see the removal procedure in Turntable Assembly (9310/L5510 Only, Din Connector) on page 6-176. 5. Remove the two screws that attach the transport flex assembly to the wrist motor.

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6. Disconnect the encoder connector on the transport flex from the encoder on the wrist motor. 7. Disconnect the wrist motor cable connector from the transport flex assembly. 8. Remove the two screws that attach the transport flex to the transport housing. 9. Remove the two screws that attach the transport flex assembly to the Z flex support bracket. 10. Disconnect the transport flex connector that connects to the Z flex circuit through a hole in the Z flex support bracket. Remove the transport flex assembly.

Replacement
1. Place the new transport flex assembly against the transport assembly. 2. Connect the transport flex connector to the Z flex circuit connector through the hole in the Z flex support bracket. 3. Seat the pinned portion of the transport flex into the recessed area of the wrist pulley housing. 4. Press the corner fold against the wrist side of the transport before securing the transport flex to the transport housing with two screws. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Attach the transport flex to the Z flex support bracket with two screws. 7. Tighten the screws to a torque of 3 Nm (26 in.-lb). 8. Connect the wrist motor cable connector to the transport flex. 9. Plug the encoder connector on the transport flex into the encoder on the wrist motor. 10. Finish attaching the transport flex to the wrist motor with the two screws. 11. Tighten the screws to a torque of 0.7 Nm (6 in.-lb). 12. Replace the turntable; see the replacement procedure in Turntable Assembly (9310/ L5510 Only, Din Connector) on page 6-178. 13. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-94. Transport Flex Assembly (9310/L5510 Only) (Sheet 1 of 2)

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Figure 6-95. Transport Flex Assembly (9310/L5510 Only) (Sheet 2 of 2)

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Z Channel Assembly (4410 Leadscrew-Driven)


The Z channel assembly is not a field replaceable unit (FRU); however, to replace the leadscrew, leadscrew bearings, Z arm bearing plate, or the counterweight bearing plate, this assembly must be removed. See Figure 6-96 on page 6-220 through Figure 6-97 on page 6-221 and use the following procedures to remove and install the Z channel assembly. WARNING: Corrosion damage: When handling the Z channel assembly, it is important to avoid touching the linear shafts and the leadscrew with your bare hands. The moisture from the skin of the fingers will cause corrosive etching of the surface and removal of the lubricant on the leadscrew. When handling any components that have the special lubricant applied to them, wear disposable plastic or latex gloves.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Remove both hands; see the removal procedure in Hand Assembly without Camera (4410 Only) on page 6-170. 4. Remove the turntable; see the removal procedure in Turntable Assembly (4410) on page 6-173. 5. Remove the two counterweights attached to the left-hand side of the counterweight plate. 6. Remove the ball lock pin from the leadscrew. 7. Lower the counterweight to the bottom onto a foam pad, compress the foam, and insert the ball lock pin into the Z channel assembly above the counterweight. 8. Disconnect the Z motor power cable connector P725 from the Z motor cable connector J725. 9. Disconnect the Z sensors and tach cable connector P728 from Z sensor to REI motherboard cable connector J728. 10. Remove the Z arm from the Z plate: a. Disconnect P731 through P735 from the Z cable bracket.

b. Disconnect camera coaxial cable connectors P736-0 and P736-1 from the Z cable bracket.

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c.

Remove the Z cable bracket from the Z plate by removing the three screws.

d. Remove the four Torx screws securing the Z arm to the Z plate and remove the Z arm. 11. Remove the two Torx screws from the flat cable clamp attaching the Z cable assembly to the Z channel. 12. Rest the Z cable assembly over the theta arm. 13. Attach two lifting handles to each side of the Z channel assembly. The top handles are mounted with the handle vertical while the bottom handles are mounted in the horizontal position. 14. Remove the eight Torx screws that secure the Z channel assembly to the end of the theta arm. 15. Lift the Z channel assembly free from the alignment pins on the theta arm, and transport the assembly to a clean work area with adequate space for disassembling the unit.

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Figure 6-96. Z Channel Assembly (Sheet 1 of 5)

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Figure 6-97. Z Channel Assembly (Sheet 2 of 5)

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Replacement
1. Attach the lifting handles to the Z channel assembly. 2. Ensure the counterweight cable is attached to the counterweight and the Z plate. 3. Move the counterweight plate to the bottom of the Z channel assembly on the foam pad, compress the foam pad, and insert a ball lock pin into the Z channel assembly above the counterweight. 4. Lift and transport the Z channel assembly to the theta arm. 5. Before attaching the Z channel assembly to the theta arm, ensure that the counterweight cable is attached to both the counterweight and Z plate. 6. Lift the Z channel assembly into position on the theta arm, and thread the eight Torx-head mounting screws (with lock washers attached) into the Z channel assembly. Note: On earlier theta arms, the machined arm required three shims between the theta arm and the Z channel assembly. To determine if shims are required, check the distance the mounting pads protrude at the end of the theta arm. If the bottom is approximately 1.27 mm (0.050 in.) greater than the top, shims are not required. Also, the machined end of the arm of earlier versions should be marked SHIMS REQUIRED. 7. Insert the three shims between the Z channel assembly and the theta arm. The shim with the three slots is mounted on the bottom mount screws, the one with four slots on the next to bottom set of screws, and the one with two slots on the next set of screws above. The top screws on the Z channel assembly are not shimmed. 8. Tighten the screws in the Z channel assembly to secure the Z channel assembly to the theta arm. 9. Tighten the screws to a torque of 5 to 7 Nm (45 to 60 in.-lb). 10. Remove the lifting handles from the Z channel assembly. 11. Remove the ball lock pin from the Z channel assembly, move the Z plate down to position the counterweight above the Z channel assembly ball lock pin hole, and insert the ball lock pin into the Z channel assembly. 12. Attach the two counterweights to the left-hand side of the counterweight plate. 13. Attach the Z cable bracket to the Z plate using three Torx-head screws. 14. Attach the Z flex and coaxial cables to the side of the Z channel using the flat cable bracket and two Torx screws previously removed. Adjust the

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cables so the loop is approximately 1/4-in. from the LSM floor when the Z plate is moved to the bottom of the Z channel. 15. Attach the Z arm to the Z plate using four Torx-head screws. 16. Tighten to a torque of 3 Nm (26 in.-lb). 17. Connect P725 and P728 to their respective connectors on the side of the Z channel assembly. 18. Connect flex cable connectors P731 through P735 to the Z cable bracket. 19. Connect coaxial connectors P736-0 and P736-1 to the Z cable bracket. 20. Replace the turntable; see the replacement procedure in Turntable Assembly (4410) on page 6-175. 21. Replace the hands; see the replacement procedure in Hand Assembly without Camera (4410 Only) on page 6-172. 22. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Z Channel Assembly (4410 Belt-Driven)


The Z channel assembly is not a FRU; however, to remove the theta arm from the theta base, this assembly must be removed. See Figure 6-98 on page 6-225 through Figure 6-100 on page 6-227 and use the following procedures to remove and install the belt driven Z channel assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii before handling any printed circuit card. 3. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 4. Insert ball locking pins below both the counterweights and the Z arm. 5. Disconnect the Z motor power cable connector P725 from the Z motor cable connector J725, freeing the cable from the clamp above. 6. Disconnect the Z sensors and tach cable connector P728 from Z sensor to REI motherboard cable connector J728 on the side of the theta arm. 7. Disconnect P731 through P735 from the Z cable bracket at the Z arm. 8. Disconnect camera coaxial cable connectors P736-0 and P736-1 from the Z cable bracket.

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9. Disconnect the MB to turntable sensor cable connector P743 from the MB card connector at the Z arm. 10. Disconnect turntable sensor cable connectors P1 CW and P1 CCW. 11. Remove the turntable flex cable from the Z arm by removing the two screws from each of the two cable brackets on the Z arm. 12. Remove the two screws attaching the Z cable assembly to the side of the Z channel. 13. Remove the three screws attaching the Z cable bracket to the Z arm. 14. Carefully rest the Z cable bracket and Z cable assembly over the end of the theta arm. 15. Insert a ball locking pin through the Z channel above the Z roller bracket. 16. Remove the hands; see the removal procedure in Turntable Assembly (4410) on page 6-173. 17. Remove the turntable; see the removal procedure in Turntable Assembly (4410) on page 6-173. 18. Remove the outer and middle counterweights from the rear counterweight. 19. Remove the Z drive belt from the rear counterweight by removing the screw below the belt slide and sliding the belt and slide out of the belt clamp. 20. Lower the rear counterweight onto a foam pad, compress the pad, and pin the Z channel above it to isolate the counterweight during the Z arm handling. 21. Attach two lifting handles to each side of the Z channel assembly. The top handles are mounted with the handle vertical while the bottom handles are mounted in the horizontal position. 22. Remove the eight Torx screws that secure the Z channel assembly to the end of the theta arm. 23. Lift the Z channel assembly free from the alignment pins on the theta arm and transport the assembly out of the LSM.

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Figure 6-98. Z Channel Assembly (Sheet 3 of 5)

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Figure 6-99. Z Channel Assembly (Sheet 4 of 5)

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Figure 6-100. Z Channel Assembly (Sheet 5 of 5)

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Replacement
1. Lift and transport the Z channel assembly to the theta arm. 2. Lift the Z channel assembly into position on the theta arm, and thread the eight Torx-head mounting screws (with lock washers attached) into the Z channel assembly. Note: On earlier theta arms, the machined arm required three shims between the theta arm and the Z channel assembly. To determine if shims are required, check the distance the mounting pads protrude at the end of the theta arm. If the bottom is approximately 1.27 mm (0.050 in.) greater than the top, shims are not required. Also, the machined end of the arm of earlier versions should be marked SHIMS REQUIRED. 3. If required, insert the three shims between the Z channel assembly and the theta arm. The shim with the three slots is mounted on the bottom mount screws, the one with four slots on the next to bottom set of screws, and the one with two slots on the next set of screws above. The top screws on the Z channel assembly are not shimmed. 4. Tighten the screws in the Z channel assembly to secure the Z channel assembly to the theta arm. 5. Tighten the screws to a torque of 5 to 7 Nm (45 to 60 in.-lb). 6. Remove the lifting handles from the Z channel assembly. 7. Remove the ball locking pin from the Z channel above the rear counterweight, lift the counterweight above the second pin hole, and insert the pin in the second pin hole. 8. Remove the ball locking pin from the Z channel above the Z roller bracket. 9. Place the end of the drive belt through the belt clamp on the rear counterweight. 10. If you have an old style belt (the last four teeth on the belt are colored), place the belt slide over the end of the belt so the four colored teeth are covered with the slide, then insert the belt and slide into the belt clamp. If you have a newer style belt (the last 10 teeth on the belt are colored), mark the fourth tooth from the end, and place the belt slide over the end of the belt so the tooth you just marked is covered with the slide. 11. Thread and tighten the screw, previously removed, into the hole below the belt slide. 12. Connect Z motor power cable connector P725 to Z motor cable connector J725, securing the cable into the clamp above.

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13. Connect the Z sensors and tach cable connector P728 to the Z sensor to REI motherboard cable connector J728 on the side of the theta arm. 14. Attach the Z cable bracket to the Z arm using three Torx-head screws. 15. Attach the Z flex and coaxial cables to the side of the Z channel using the two screws previously removed. 16. Attach the turntable flex cable assembly brackets to the Z arm using the four screws previously removed. 17. Connect flex cable connectors P731 through P735 to the Z cable bracket. 18. Connect coaxial connectors P736-0 and P736-1 to the Z cable bracket. 19. Connect the MB to turntable sensor cable connector P743 from the MB card connector. 20. Connect the turntable sensor cable connectors P1-CW and P1-CCW to their respective connectors. 21. Attach the middle and outer counterweights to the rear counterweight 22. Tighten the screws to a torque of 3 Nm (26 in.-lb). 23. Replace the turntable; see the replacement procedure in Turntable Assembly (4410) on page 6-175. 24. Replace the hands; see the replacement procedure, in Hand Assembly without Camera (4410 Only) on page 6-172. 25. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 26. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Sensor and Tach Cable Assembly (4410)


See Figure 6-101 on page 6-231 through Figure 6-104 on page 6-235 and use the following procedures to remove and replace the Z sensor and tachometer cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Disconnect cable connector P-726 from the Z motor/encoder tach cable connector J-726. 3. Disconnect cable connectors P727-X from each of the ME card connectors. 4. Disconnect cable connector P728 from J728 on the theta arm. 5. Free the Z sensor and tach cable from the cable clamps.

Replacement
1. Connect cable connector P728 to J728 on the theta arm. 2. Connect cable connectors P727-X to each of the ME card connectors. 3. Connect cable connector P-726 to the Z motor/encoder tach cable connector J-726. 4. Secure the cable inside the clamps attached to the side of the Z channel. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-101. ME Card (Sheet 1 of 3)

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Figure 6-102. ME Card (Sheet 2 of 3)

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Figure 6-103. ME Card (Sheet 3 of 3)

Z Leadscrew/Mount Assembly (4410)


To remove and replace the Z leadscrew with mount, the Z channel assembly must be removed from the theta arm. See Figure 6-105 on page 6-236 and Figure 6-106 on page 6-240 and use the following procedures to remove and replace the Z leadscrew with ballnut:

Removal
1. Remove the Z channel assembly from the theta arm; see the removal procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 7-218. 2. Lay the Z channel assembly on a work surface with the Z plate facing upward. 3. Remove the four Torx-head screws that hold the leadscrew ballnut mount to the Z plate.

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4. Insert a ball lock pin through the Z channel assembly below the counterweight bearing plate to prevent the counterweight plate from rolling off its shaft. 5. Remove the counterweight cable from the Z plate. 6. Loosen the Z motor mounting screws, turn the motor assembly to loosen the belt, and remove the belt from the leadscrew pulley. 7. Remove the Z belt pulley from the leadscrew shaft on top of the Z channel assembly top bearing plate by loosening the allen-head screw. 8. Loosen the allen-head set screw in the front of the bottom bearing plate. This screw holds the leadscrew spacer aligned with the bottom plate for pinning the leadscrew. 9. Remove the four Torx-head screws from the bottom bearing plate assembly of the Z channel assembly. 10. Support the leadscrew as the bottom plate is removed. 11. Move the Z plate to the bottom of the Z channel assembly and secure it to prevent it from coming off the linear shafts. 12. Move the leadscrew down until it is clear of the top bearing plate, then lift the top end of the leadscrew and withdraw it from the hole in the Z plate ballnut mount bracket and out of the Z channel assembly. Note: If the new leadscrew contains bearings, skip to Step 3 of the replacement procedure. 13. Remove the snap ring from the leadscrew below the bottom bearing. CAUTION: Bearing alignment: When removing the bearings from the shaft in the following steps, keep the bearing aligned with the shaft to prevent binding. If it binds, do not try to force it off; instead, push it back on the shaft and try again. 14. Remove the inner preload spring, lower bearing, spacer, and upper bearing from the shaft. 15. Remove the snap ring from the top end of the leadscrew shaft, and remove the inner preload spring, the top bearing, spacer, and bottom bearing from the shaft.

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Figure 6-104. Z Leadscrew With Ballnut (Sheet 1 of 2)

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Figure 6-105. Z Leadscrew With Ballnut (Sheet 2 of 2)

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Replacement
CAUTION: Bearing alignment: When installing the bearings onto the leadscrew shaft, the bearing must be aligned with the shaft to prevent binding. Any force could damage the bearing race and/or the leadscrew shaft. If binding occurs, remove the bearing, align the bearing, and try again. 1. Install a bearing, spacer, bearing, and preload spring onto the top of the leadscrew shaft, and secure with a snap ring. 2. Install a bearing, spacer, bearing, and preload spring onto the bottom of the leadscrew shaft, and secure with a snap ring. 3. Insert the outer preload spring into the top plate if it was removed during the removal procedure of the leadscrew. 4. Place the lower portion of the leadscrew through the Z plate and, with the leadscrew top bearings aligned with the top plate, guide the bearings into the top plate. 5. Hold the lower spacer, and turn the leadscrew until the hole in the leadscrew shaft is aligned with the hole in the spacer. 6. Turn the spacer and leadscrew until the holes are aligned with the hole in the bottom plate. 7. Align the leadscrew bearings up with the bottom plate, and guide the bottom plate onto the leadscrew bearings. 8. Make sure that the ball lock pin hole in the bottom plate, spacer, and leadscrew shaft are all aligned. 9. Thread and tighten the four Torx-head screws in the bottom plate. 10. Tighten the screws to a torque of 3 Nm (26 in.-lb). 11. Tighten the set screw in the bottom bearing plate to prevent the spacer from rotating inside the bearing plate. 12. Ensure that the ball lock pin holes are aligned in the bearing plate and spacer before tightening the set screw. 13. Move the Z plate on the leadscrew until it mates with the ballnut. Align the holes and secure the ballnut plate with the Z plate mounting bracket with four Torx-head screws. 14. Tighten the screws to a torque of 3 Nm (26 in.-lb). 15. Attach the Z belt pulley to the top of the leadscrew shaft, and align the pulley with the motor pulley. 16. Place a 12-in. steel ruler across both pulleys, and adjust the leadscrew pulley until aligned.

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17. Tighten the allen-head screw in the leadscrew pulley. 18. Tighten the screw to a torque of 2 Nm (18 in.-lb). 19. Turn the motor mount, and attach the belt over both pulleys. 20. Attach the belt tension spring and, with the tension provided by the spring, tighten the four Torx-head bolts securing the motor plate to the Z channel assembly top plate. 21. Tighten the bolts to a torque of 3 Nm (26 in.-lb). 22. Attach the counterweight cable to the counterweight and to the Z plate. 23. Check the routing of the cable to ensure that it is properly positioned over the two pulleys on the top plate. 24. Attach the Z channel assembly to the theta arm; see the replacement procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218 or Z Channel Assembly (4410 Belt-Driven) on page 6-223.

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Counterweight Plate Bearings (4410)


Removal of the counterweight plate bearings requires the Z channel assembly to be removed from the theta arm. See Figure 6-106 on page 6-240 and use the following procedures to remove and replace the bearings. CAUTION: Bearing damage: Keep the counterweight plate aligned with the two shafts as the plate is removed or replaced onto the Z channel assembly shafts, or damage will occur to the bearings. If it binds, the ball bearings will be forced out of the assembly. Sighting down the shafts from the end of the Z channel assembly provides the best means of keeping the plate aligned. If it does bind, do not use force to move it.

Removal
1. remove the Z channel and move it to a work surface where the Z channel assembly can be placed horizontally; see the removal procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218. 2. Remove the ball lock pin from the Z channel assembly above the counterweight plate, move the counterweight plate up above the ball lock pin hole, and insert the ball lock pin back into the hole. 3. Disconnect the counterweight cable from the right-hand counterweight, and remove the right-hand counterweight from the counterweight plate. 4. Loosen the allen-head set screw in the front of the bottom bearing plate. 5. Remove the four Torx screws attaching the bottom bearing plate. 6. Support the leadscrew, and remove the bottom bearing plate. 7. Remove the ball lock pin from the Z channel assembly and carefully remove the counterweight plate from the shafts. 8. Remove the three 6-32 x 1/2-in. Torx screws that hold the bearings from the side of the plate. 9. Push the three bearings out of the plate, being careful not to jar any ball bearings loose.

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Figure 6-106. Counterweight Plate Bearing

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Replacement
1. Take each new bearing and squeeze it into place in the plate, aligning the hole in the side of each bearing with the hole for the Torx screw. 2. Insert each Torx screw through the plate and into the bearing. 3. Tighten the screw to a torque of 1.4 Nm (12 in.-lb). CAUTION: Bearing damage: Use extreme care to prevent bearing damage in the following steps. 4. Align the counterweight plate bearings with the two shafts on the Z channel assembly, and mount the plate onto the Z channel assembly top side up. 5. Slide the counterweight plate up the Z channel shafts, and insert the ball lock pin into the Z channel assembly below the counterweight plate. 6. Align the leadscrew shaft hole with the hole in the spacer between the two lower bearings. 7. Align the bearings of the leadscrew with the bottom plate, and insert the bottom plate onto the bearings. The holes in the leadscrew and spacer should align with the ball lock pin hole in the bottom plate. 8. Thread and tighten the four Torx-head screws in the bottom plate. 9. Tighten the screws to a torque of 3 Nm (26 in.-lb). 10. Tighten the set screw in the bottom plate. 11. Ensure that the ball lock pin holes in the bottom plate and the leadscrew spacer are aligned before the set screw is tightened. 12. Install the right-hand counterweight to the counterweight bearing plate with two Torx screws. 13. Tighten the screws to a torque of 3 Nm (26 in.-lb). 14. Attach the counterweight cable to the counterweight. 15. Attach the other two counterweights. 16. Installing the Z channel assembly to the theta arm; see the replacement procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218.

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Z Plate Bearings (4410)


Removal of the Z plate bearings requires the Z channel assembly to be removed from the theta arm. See Figure 6-107 on page 6-243 and use the following procedures to remove and replace the bearings. WARNING: Bearing damage: Keep the Z plate aligned with the two shafts as the plate is removed or replaced onto the Z channel shafts or damage will occur to the bearings. If it binds, the ball bearings will be forced out of the assembly. Sighting down the shafts from the end of the Z channel assembly provides the best means of keeping the plate aligned. If it does bind, do not use force to move it.

Removal
1. Remove the Z channel assembly and move the Z channel assembly to a work surface where the Z channel assembly can be placed horizontally; see the removal procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218. 2. Remove the ball lock pin from the Z channel assembly, move the counterweight plate up, and insert the ball lock pin back into the hole beneath the counterweight plate. 3. Loosen the allen-head set screw in the front of the bottom bearing plate. 4. Remove the four Torx-head screws from the leadscrew ballnut mount plate. 5. Remove the counterweight cable from the Z plate. 6. Support the leadscrew, and remove the bottom Z channel plate. 7. Carefully remove the Z plate from the two shafts on the Z channel assembly. 8. Remove the three 6-32 x 1/2-in. Torx screws that hold the bearings into the plate. 9. Push the bearings out, being careful not to jar any ball bearings loose.

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Figure 6-107. Z Arm Plate Bearing Assembly

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Replacement
1. Take each new bearing and squeeze it into place in the plate, aligning the hole in the side of each bearing with the hole for the set screw. 2. Insert each Torx screw through the plate and into the bearing. 3. Align the Z plate bearings with the two shafts on the Z channel assembly and mount the plate onto the Z channel assembly. CAUTION: Bearing damage: Use extreme caution to prevent bearing damage. 4. Slide the Z plate up the Z channel shafts and attach the leadscrew ballnut mount to the Z plate bracket using four Torx-head screws. 5. Align the leadscrew shaft hole with the hole in the spacer between the two lower bearings. 6. Align the bearings of the leadscrew with the bottom plate and insert the bottom plate onto the bearings. The holes in the leadscrew and spacer should align with the ball lock pin hole in the bottom plate. 7. Thread and tighten the four Torx-head screws in the bottom plate. 8. Tighten the set screw in the bottom bearing plate. 9. Ensure that the ball lock pin holes in the bottom bearing plate and the leadscrew spacer are aligned before tightening the set screw. 10. Attach the counterweight cable to the Z plate. 11. Install the left-hand and outer-counterweights to the counterweight plate. 12. Install the Z channel assembly to the theta arm; see the replacement procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218.

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Z Leadscrew Top/Bottom Bearings (4410)


To remove and replace the Z leadscrew bearings, the Z channel assembly must be removed from the theta arm. Use the procedure in Z Leadscrew/Mount Assembly (4410) on page 6-233, Figure 6-104 on page 6-235, and Figure 6-105 on page 6-236 first. Then remove and replace the Z leadscrew bearings, as shown in Figure 6-108 on page 6-248 and Figure 6-109 on page 6-249.

Removal
1. Remove the Z channel assembly from the theta arm; see the removal procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218. 2. Lay the Z channel assembly on a work surface with the Z plate facing upward. 3. Remove the four Torx-head screws from the leadscrew ballnut mount. 4. Remove the ball lock pin from the Z channel assembly, move the counterweight plate up, and insert the ball lock pin back into the hole below the counterweight plate to prevent the counterweight plate from rolling off its shaft. 5. Remove the counterweight cable from the Z plate. 6. Loosen the Z motor mounting screws, turn the motor assembly to loosen the belt, and remove the belt from the leadscrew pulley. 7. Remove the Z belt pulley from the leadscrew shaft on top of the Z channel top bearing plate by loosening the allen-head screw. 8. Loosen the allen-head set screw in the front of the bottom bearing plate. 9. Remove the four Torx-head screws from the bottom bearing plate assembly of the Z channel assembly. 10. Support the leadscrew as the bottom plate is removed. 11. Move the Z plate to the bottom of the Z channel assembly and secure it to prevent it from coming off the shafts. 12. Move the leadscrew down until it is clear of the top bearing plate. 13. Lift the top end of the leadscrew, and withdraw it from the hole in the Z plate ballnut mount bracket and out of the Z channel assembly. 14. Remove the snap ring from the leadscrew below the bottom bearing. 15. Remove the inner preload spring, lower bearing, spacer, and upper bearing from the shaft.

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CAUTION: Bearing damage: When removing the bearings from the shaft, keep the bearing aligned with the shaft to prevent binding. If it binds, do not try to force it off; instead, push it back on the shaft and try again. 16. Remove the snap ring from the top end of the leadscrew shaft, and remove the inner preload spring, the top bearing, spacer, and bottom bearing from the shaft.

Replacement
CAUTION: Bearing damage: When installing the bearings onto the leadscrew shaft, keep the bearing aligned with the shaft to prevent binding. Any force could damage the bearing race and/or the leadscrew shaft. If binding occurs, remove the bearing, align the bearing, and try again. 1. Install the new bearings with a spacer between, the inner preload spring, and the snap ring to secure them to the leadscrew shaft. 2. Align the hole in the leadscrew shaft with the hole in the spacer. 3. Insert the outer preload spring into the top plate if it was removed during the removal procedure of the leadscrew. 4. Place the lower portion of the leadscrew through the Z plate mount and with the leadscrew top bearings aligned with the top plate, guide the bearings into the top plate. 5. Hold the lower spacer, and turn the leadscrew until the hole in the leadscrew shaft is aligned with the hole in the spacer. 6. Turn the spacer and leadscrew until the holes are aligned with the hole in the bottom plate. 7. Align the leadscrew bearings with the bottom plate, and guide the bottom plate onto the leadscrew bearings. Make sure that the ball lock pin hole in the bottom plate, spacer, and leadscrew shaft are all aligned. 8. Thread and tighten four Torx-head screws in the bottom plate. 9. Tighten the set screw in the bottom bearing plate. Ensure that the ball lock pin holes in the bottom plate and the leadscrew spacer are aligned before tightening the set screw. 10. Move the Z plate on the leadscrew until it mates with the ballnut. Align the holes, and secure the ballnut plate with the Z plate mounting bracket with four Torx-head screws. 11. Attach the Z belt pulley to the top of the leadscrew shaft, and align the pulley with the motor pulley.

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12. Place a 12-in. steel ruler across both pulleys, and adjust the leadscrew pulley until aligned. 13. Tighten the allen-head screw in the leadscrew pulley. 14. Turn the motor mount and attach the belt over both pulleys. 15. Attach the belt tension spring and, with the tension provided by the spring, tighten the four Torx-head bolts securing the motor plate to the Z channel top plate. 16. Attach the counterweight cable to the counterweight and to the Z plate. 17. Check the routing of the cable to ensure it is properly positioned over the two pulleys on the top plate. 18. Attach the left-hand and outer counterweights to the counterweight plate. 19. Attach the Z channel assembly to the theta arm; see the replacement procedure in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218.

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Figure 6-108. Z Leadscrew Top/Bottom Bearings (Sheet 1 of 2)

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Figure 6-109. Z Leadscrew Top/Bottom Bearings (Sheet 2 of 2)

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Counterweight Pulley Assembly (4410)


See Figure 6-110 on page 6-251 and use the following procedures to remove and replace the counterweight pulley assembly. If desired, remove the Z channel assembly first and replace the Z channel assembly; see the procedures in Z Channel Assembly (4410 Leadscrew-Driven) on page 6-218.

Removal
1. See LSM Entry Procedure on page xliv. 2. Lift the Z cable counterweight by forcing the Z arm down, and insert a ball locking pin through the Z channel assembly beneath the counterweight. 3. Lift on the Z arm until the cable is slack enough to remove from the Z plate, and pin the leadscrew at the bottom of the Z channel with a ball locking pin through the bottom plate. 4. Remove the cable guard from the cable pulley bracket by removing the two Torx screws (or the guard can just be loosened and left attached). 5. Remove the cable from the Z plate, and route it out of the pulleys. 6. Remove the cable pulley bracket by removing the two Torx-head screws from the top of the bracket that secure it to the Z channel top plate.

Replacement
1. Place the cable pulley bracket on top of the Z channel top plate, and align the mounting holes and pins. 2. Thread and tighten the two Torx-head screws to secure the pulley bracket to the top plate. 3. Route the cable end through the hole in the top plate, over the rear pulley, down over the front pulley, through the hole in the top plate, and connect it to the Z plate. 4. Attach the cable guard to the cable pulley bracket with two Torx-head screws. 5. Remove the ball locking pin from the leadscrew at the Z channel bottom plate. 6. Force the Z arm down, and remove the ball locking pin from the Z channel assembly that was supporting the counterweight. 7. Move the Z arm from limit to limit to check for proper operation. 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-110. Counterweight Pulley Assembly

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Counterweight Cable (4410)


See Figure 6-111 on page 6-253 and use the following procedures to remove and replace the Z channel assembly counterweight cable.

Removal
1. See LSM Entry Procedure on page xliv. 2. Raise the counterweight by forcing the Z arm down until the counterweight is above the ball lock pin holes in the Z channel assembly. Place a ball lock pin through the Z channel assembly below the counterweight. 3. Move the Z arm up until the cable is slack, and pin the Z leadscrew at the bottom plate. 4. Remove the outer and left-hand counterweights, and disconnect the cable ball end from the slot in the right-hand counterweight. 5. Remove the cable guard from the cable pulley bracket by removing the two Torx screws (or the guard can be loosened and left attached). 6. Detach the cable from the Z plate, and pull the cable from the pulley assembly mounted on the right-hand side of the top plate assembly.

Replacement
1. Route the replacement cable around the two top plate pulleys and down through the holes in the top plate (at the end of the pulley bracket). 2. Connect the cable end toward the front of the Z channel to the slot in the Z plate. 3. Connect the other cable end to the slot in the right-hand counterweight and tighten the cable guard. 4. Attach the left-hand and outer-counterweights. 5. Remove the ball locking pin from the Z leadscrew at the bottom plate. 6. Move the Z arm to remove the slack from the cable, and ensure that the cable is positioned over the pulleys. 7. Lift the counterweights by forcing the Z arm down, and remove the ball locking pin from the Z channel. 8. Move the Z arm from limit to limit to ensure proper operation. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-111. Z Channel Assembly Counterweight Cable

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Z Belt-Drive Pulley Assembly (4410)


See Figure 6-112 on page 6--255and use the following procedures to remove and replace the Z belt drive pulley assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Insert ball locking pins below both the counterweight and Z arm. 4. Remove the front counterweight. 5. Remove the screw below the belt slide on rear counterweight. 6. Lower the belt slide to disengage the belt from the belt clamp. 7. Pull the belt until it is free of the belt drive pulley assembly. 8. Loosen the two machine screws in the outer coupling on the belt drive pulley shaft. 9. Remove the two 10-32 screws from the bottom of the top plate that secures the belt drive pulley assembly to the plate. 10. Lift the belt drive pulley assembly off the top plate. 11. Slide the coupling off the belt drive pulley shaft.

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Figure 6-112. Z Belt Drive Pulley Assembly

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Replacement
1. Slide the outer coupling (previously removed from the old unit) onto the replacement unit shaft. Do not tighten screws. 2. Place the belt drive pulley assembly on top of the Z channel top plate, and align the mounting holes and pins. 3. Thread and tighten the two screws to a torque of 3 Nm (26 in.-lb). to secure the belt drive pulley assembly to the top plate. 4. Place the middle coupling between the two outer couplings, and mate the surfaces. 5. Slide the coupling on the belt drive pulley side until all three couplings are fully mated. 6. Tighten the two machine screws in the outer coupling. Note: If both outer couplings have been loosened and moved on the two shafts, position the outer coupling on the belt pulley shaft 6.3 mm (0.25 in.) from the belt pulley bracket, tighten the screws, and perform the two previous steps. 7. Feed the drive belt up and over the two pulleys of the pulley assembly and down through the belt clamp on the rear counterweight. 8. If you have an old version belt (the last four teeth are colored), place the belt slide over the four colored teeth on the end of the belt. If you have a newer version belt (the last 10 teeth are colored), mark the fourth tooth from the end, and place the belt slide over the first four teeth so that the tooth you marked is not visible. 9. Slide the belt and belt slide into the belt clamp. 10. Thread and tighten the screw into the hole below the belt slide. 11. Attach the front counterweight to the middle counterweight using the screws previously removed. 12. Tighten the screws to a torque of 3 Nm (26 in.-lb). 13. Remove the ball locking pins from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Drive Belt (4410)


See Figure 6-113 on page 6-258 and use the following procedures to remove and replace the Z drive belt.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Insert ball locking pins below both the counterweight and Z arm. 4. Remove the front counterweight. 5. Remove the screw below the belt slide on the rear counterweight. 6. Lower the belt slide and belt out of the belt clamp to disengage the belt. 7. Remove the screw below the belt slide on the rear of the Z arm. 8. Lower the belt slide and belt to disengage the belt from the belt clamp. 9. Pull the belt through the belt drive pulley assembly until it is free.

Replacement
1. Route the replacement belt over the two drive pulleys and down through the holes in the top plate. 2. Mark the fourth tooth from one end of the belt, place the belt slide over the last four teeth so that the tooth you marked is not visible, and insert the belt and belt slide into the belt clamp on the Z arm. 3. Thread and tighten the screw into the hole below the belt slide. 4. Mark the fourth tooth from the free end of the belt, place the belt slide over the last four teeth so that the tooth you marked is not visible, and insert the belt and belt slide into the belt clamp on the rear counterweight. 5. Thread and tighten the screw into the hole below the belt slide. 6. Attach the front counterweight to the middle counterweight using the screws previously removed. 7. Tighten the screws to a torque of 3 Nm (26 in.-lb). 8. Remove the locking pins from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-113. Z Drive Belt And Slide

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Z Drive Belt Slide (4410)


See Figure 6-113 on page 6-258 and use the following procedures to remove and replace the Z drive belt slide.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Insert ball locking pins below both the counterweight and Z arm. 4. If replacing the counterweight belt slide: a. Remove the front counterweight.

b. Remove the screw below the belt slide on the rear counterweight. c. Lower the belt slide and belt out of the belt clamp to disengage the belt and belt slide from the belt clamp.

5. If replacing the Z arm belt slide: a. Remove the screw below the belt slide on the rear of the Z arm.

b. Lower the belt slide and belt to disengage the belt and belt slide from the belt clamp.

Replacement
1. If you have an older version belt (the last four teeth are colored), place the belt slide over the four colored teeth of the belt and slide the belt and belt slide into the belt clamp. If you have a newer version belt (the last 10 teeth are colored), mark the fourth tooth from the end and place the belt slide over the teeth of the belt so that the tooth you marked is not visible. 2. Thread and tighten the screw into the hole below the belt slide. 3. If replacing the counterweight belt slide: a. Attach the front counterweight to the middle counterweight using the screws previously removed.

b. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Remove the locking pins from the Z channel assembly and move the Z arm from limit to limit to check for unrestricted movement. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Z Roller Assembly (4410 Belt-Driven Z)


See Figure 6-114 on page 6-261 and use the following procedures to remove and replace the Z roller assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Raise the counterweight by forcing the Z arm down until the counterweight is above the second pin hole from the bottom of the Z channel assembly. Place a ball locking pin through the Z channel assembly below the counterweight. 3. Support the roller assembly while removing the three 10-32 x 3/4-in. screws from attaching the roller assembly to the Z arm.

Replacement
1. Place the roller assembly on the roller plate with rollers positioned at the top of the assembly. 2. Align the three holes in the Z arm with the three holes in the roller assembly. 3. Attach the roller assembly to the Z arm with the three screws previously removed. 4. Tighten the screws to a torque of 3 Nm (26 in.-lb). 5. Remove the ball locking pin from the Z channel below the counterweight. 6. Carefully move the Z arm in and out of its limits of play while checking the flag for proper clearance through the ME card sensors. If the flag does not clear the sensors, perform the following steps to adjust the sensors (see Figure 6-114 on page 6-261). a. Loosen the two screws securing the sensor card mount to the Z channel and move the Z arm up and down so that the flag is in the sensor but does not hit the sensor. (The Z arm is spring-loaded so that, if it is released, it will be forced outward from the center of the LSM. The Z arm must be in this position while making the sensor adjustments.)

b. Adjust the sensor card mount so that there is a 0.51-mm (0.020-in.) gap between the inside edge of the flag and the sensor (the flag will not be centered between the sensors). c. Tighten the two screws securing the sensor card mount to the Z channel.

d. Again move the Z arm in and out of its limits of play to check that the flag clears the sensors. 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-114. Z Roller Bearing Assembly

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Z Roller Plate (4410 Belt-Driven Z)


See Figure 6-114 on page 6-261 and use the following procedures to remove and replace the Z roller plate assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Lower the Z arm to the bottom of the Z channel. 3. Support the roller assembly while removing the three 10-32 x 3/4-in. screws from attaching the roller assembly to the Z arm. 4. Open the Z arm slightly to gain access to the roller plate. 5. Remove the 18 screws attaching the roller plate to the Z channel.

Replacement
1. Align the holes in the roller plate with the holes in the Z channel. 2. Thread the 18 screws previously removed to secure the roller plate to the Z channel. 3. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Place the roller assembly on the roller plate with rollers positioned at the top of the assembly. 5. Align the three holes in the Z arm with the three holes in the roller assembly. 6. Attach the roller assembly to the Z arm with the three screws previously removed. 7. Tighten the screws to a torque of 3 Nm (26 in.-lb). 8. Move the Z arm from limit to limit to check for unobstructed travel. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Optical Roll Sensor Cable Assembly (4410)


See Figure 6-115 on page 6-264 and use the following procedures to remove and replace the assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Remove two #6 Torx screws from the top of the end stop bracket. 4. Remove two #2 pan-head screws from beneath the end stop bracket to release the sensor from the bracket. 5. Remove the screw holding the cable clamp on the outer tube. 6. Disconnect P761 from J761 by depressing the latch on the center of the plug. 7. Repeat the procedure for the second roll sensor and end stop bracket and retain the brackets.

Replacement
1. Connect P761 to J761 by depressing the latch on the center of the plug. 2. Screw the cable clamp onto the outertube. 3. Thread and tighten two #2 pan-head screws beneath the end stop bracket. 4. Thread and tighten two #6 Torx screws to the top of the end stop bracket. 5. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-115. Optical Roll Sensor Cable Assembly

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Roll Flat Flex Cable Assembly (4410)


See Figure 6-116 on page 6-266 and use the following procedures to remove and replace the roll flat flex cable assembly located on the hand assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Unwrap the two Velcro loops from the roll flat flex cable assembly. 4. Remove the two Torx screws attaching the MD card cable clamp to the MD card, and remove the clamp. 5. Disconnect P775 by pressing the ears together. 6. Remove two screws from the baseplate cable clamp on the baseplate, and remove the clamp. 7. Disconnect P756 from the MS card by pressing the ears together.

Replacement
1. Connect P756 at the MS card. 2. Attach the cables to the baseplate with the baseplate cable clamp, mating the slot in the clamp to the strain relief on the coaxial cable. 3. Connect P775. 4. Attach the MD card cable clamp and cables to the MD card, mating the slot in the clamp to the strain relief on the coaxial cable. 5. Wrap the two Velcro loops around the roll flat flex cable assembly so that the roll flex coaxial cable assembly is placed between the Velcro hooks and loops and is at the edge of the roll flat flex cable assembly. 6. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-116. Roll Flat Flex Cable Assembly

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Roll Flex Coaxial Cable Assembly (4410)


See Figure 6-117 on page 6-268 and Figure 6-118 on page 6-269 and use the following procedures to remove and replace the roll flex coaxial cable assembly on the hand assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Disconnect cable connector P785 from camera connector J785. 4. Cut the three cable ties attaching the cable to the camera cable bracket. 5. Unwrap the two Velcro loops from the coaxial cable assembly. 6. Remove the two screws attaching the MD card cable clamp to the MD card. 7. Remove the two screws from the baseplate cable clamp, and remove the clamp from the baseplate. 8. Disconnect the cable connector P782-X from the turntable connector J782-X.

Replacement
1. Connect the roll flex coaxial cable connector P782-X to the turntable connector J782-X. 2. Attach the cables to the baseplate with the baseplate cable clamp, mating the slot in the clamp to the strain relief on the coaxial cable. 3. Attach the cables to the MD card with the MD card cable clamp, mating the slot in the clamp to the strain relief on the coaxial cable. 4. Route the cable through the slot in the MD card (old style) and between the MD card and the reach motor/encoder assembly as shown. 5. Connect the cable connector P785 to the camera connector J785. 6. Attach the three cable ties as shown (PN 10075021 attaches to the tie mount). (The cable ties should be in the ISP.) 7. Wrap the two Velcro loops around the roll flat flex cable assembly so that the roll flex coaxial cable assembly is placed between the Velcro hooks and loops and is at the edge of the roll flat flex cable assembly. 8. Remove the locking pin(s) from the Z channel assembly and move the Z arm from limit to limit to check for unrestricted movement. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-117. Roll Flex Coaxial Cable Assembly (Sheet 1 of 2)

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Figure 6-118. Roll Flex Coaxial Cable Assembly (Sheet 2 of 2)

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Cable Assembly (4410)


See Figure 6-119 on page 6-271 and Figure 6-120 on page 6-272 and use the following procedures to remove and replace the Z to turntable cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Disconnect coaxial BNC connectors P782-0 and P782-1 from the turntable. 4. Disconnect flex cable connectors P750, P751, P752, and P753 from their respective connectors on the turntable. 5. Disconnect the MB to turntable sensor cable connectors P1 CW and P1 CCW from the turntable sensor connectors. 6. Disconnect the MB to turntable sensor cable connector P743 from the MB card connector. 7. Remove the two Torx screws securing the cable bracket to the turntable. 8. Remove the two cable clamps from the top of the turntable and the two clamps from the coaxial cable brackets. 9. Keep the screws and clamps for attaching the new cables to the turntable. 10. Remove two cable clamps from the turntable. 11. Remove the two cable clamp brackets from the side of the Z arm by removing the two Torx screws from the Z arm. 12. Leave the cables clamped inside the clamp/cable clamp bracket. 13. Disconnect the two coaxial cable BNC connectors from the Z cable bracket. 14. Disconnect the four flex cable connectors from the Z cable bracket.

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Figure 6-119. Z to Turntable Cable Assembly (Sheet 1 of 2)

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Figure 6-120. Z to Turntable Cable Assembly (Sheet 2 of 2)

Replacement
1. Attach the two cable clamp brackets on the cable assembly to the side of the Z arm using two Torx-head screws to secure each bracket to the Z arm. 2. Attach the cable bracket to the top of the turntable using two Torx-head screws. 3. Attach two cable clamps to the turntable. 4. Connect the two coaxial camera BNC connectors to the Z plate cable bracket. 5. Connect the four flex cables to the Z cable bracket.

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6. Connect the MB to turntable sensor cable connectors P1 CW and P1 CCW to the respective turntable sensor connectors. 7. Connect the MB to turntable sensor cable connector P743 to the MB card connector. 8. Connect P782-0 and P782-1 coaxial connectors to their respective turntable connectors. 9. Secure coaxial cables P782-0 and P782-1 to the coaxial cable brackets with the two cable clamps and screws previously removed. 10. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 11. Secure coaxial cable P782-1 to the top of the turntable with the two clamps and screws previously removed. 12. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 13. Connect flex cable connectors P750 through P753 to their respective turntable connectors. 14. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 15. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Optical Sensor Cable Assembly4410 Turntable


See Figure 6-121 on page 6-274 and use the following procedures to remove and replace one or two optical sensor cable assemblies from the turntable sensor plate assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Pin the Z channel to position the turntable at the proper height; see Pinning Procedure4410 Z Channel on page 6-101. 3. Disconnect J1 from the respective P1 CW or CCW connector. 4. Remove the Torx screw from the cable clamp. 5. With an offset Torx screwdriver, remove the two screws attaching the optical sensor cable assembly to the turntable sensor plate assembly.

Replacement
1. With an offset Torx screwdriver, thread and tighten the two screws attaching the optical sensor cable assembly to the turntable sensor plate assembly. 2. Thread and tighten the Torx screw into the cable clamp.

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3. Connect J1 to the respective P1 CW or CCW connector. 4. Check the position by turning the turntable. The sensor blade should slide through the center of the optical sensor cable assembly. 5. Remove the locking pin(s) from the Z channel assembly, and move the Z arm from limit to limit to check for unrestricted movement. 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures. Figure 6-121. Turntable Optical Sensor Cable Assembly

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LSM Hand and Interior Ceiling Lamps


On the 4410 LSM, there are eleven lamps: two per camera, six in the roof sections, and one in the lower roof gusset. The 9310/L5510 LSM uses LED light arrays in place of the camera lamps. The lamps on the camera and gusset are removed and replaced using following procedure. The lamps in the roof are removed and replaced per the second following procedure.

Camera and Gusset Lamps Removal


1. See LSM Entry Procedure on page xliv. 2. While holding onto the lamp with one hand, move the lever beside the lamp to eject the lamp from the socket.

Camera and Gusset Lamps Replacement


1. Align the two pins of the lamp with the lamp socket. 2. Press the lamp into the socket until seated firmly. 3. Remove and reseat the other lamps on the two hands. Ensure that all of the lamps are seated firmly into the lamp sockets. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Roof Lamp Removal


1. See LSM Entry Procedure on page xliv. 2. Remove the four outside Torx screws on the bracket. The light fixture drops down. 3. While holding onto the lamp with one hand, move the lever beside the lamp to eject the lamp from the socket.

Roof Lamp Replacement


1. Align the two pins of the lamp with the lamp socket. 2. Press the lamp into the socket until seated firmly. 3. Attach the fixture into the bracket with four Torx screws. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Warning Light Lamps


Use the following procedures to remove and replace the warning lights located on the roof inside the LSM.

Removal
1. See LSM Entry Procedure on page xliv. 2. On the front panel, loosen two thumbscrews, lift the panel up and out of the slot, and drop it down. 3. Pull out the bulbs that are burned out.

Replacement
1. Insert the new bulbs. 2. Lift the front panel back into the slot, and tighten the two thumbscrews. 3. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Thermal Switch AssemblyInner Roof Gusset


See Figure 6-122 on page 6-277 and use the following procedures to remove and replace the lower gusset thermal switch assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway). Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 3. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 4. On the lower gusset, disconnect P858 from J858. 5. Remove the two #10 Torx screws attaching the assembly to the gusset.

Replacement
1. Attach the assembly to the gusset with the two screws. 2. Connect P858 to J858. 3. Close, align, and secure the inner door. 4. Use the alignment marks to position the door.

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5. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 6. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures. Figure 6-122. Thermal Switch AssemblyInner Roof Gusset

Temperature Sensor (BY Card, Lower Gusset)


See Figure 6-122 and the following procedures to remove and replace the lower gusset temperature sensor.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the inner door by removing the two bolts on the top left-hand side and the bolt on the top right-hand side (as viewed from the access doorway).

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3. Scribe alignment marks on the inner door and adjacent inner wall if none were scribed during installation of the LSM. 4. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 5. On the lower gusset, disconnect P330-A from the top of the BY card. 6. Unsnap the sensor from the bracket.

Replacement
1. Snap the sensor onto the bracket. 2. Connect P330-A onto the top of the BY card. 3. Close, align, and secure the inner door. 4. Use the alignment marks to position the door. 5. Install the two bolts on the upper left-hand side and one bolt on the upper right-hand side. 6. Tighten the bolts to a torque of 20 to 24 Nm (180 to 216 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Temperature Sensor (BY Card, LCU Wall)


See Figure 6-123 on page 6-279 and use the following procedures to remove and replace the LCU wall temperature sensor.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Disconnect P330-B from the top of the BY card. 4. Unsnap the sensor from the bracket.

Replacement
1. Snap the sensor onto the bracket. 2. Connect P330-B onto the top of the BY card. 3. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-123. Temperature Sensor (BY Card, LCU Wall)

ND CardStandard Door
See Figure 6-124 on page 6-281 and use the following procedures to remove and replace the ND card located on the library side of the access door.

Removal
1. See LSM Entry Procedure on page xliv. 2. Have the customer eject any tape cartridges occupying Row 5, Columns 12 through 22 of the access door before taking the LSM offline. 3. Open the CAP door. 4. Remove the two screws that attach the right-hand array in Row 10 of the access door and remove the array. 5. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 6. Disconnect P889 from J889 on the ND card. 7. Remove the two #6 Torx screws attaching the ND card.

Replacement
1. Attach the ND card with the two Torx screws. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb).

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3. Connect P889 to J889. 4. Attach the array with the two screws. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Close the CAP door. 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

LAD Switch and Cable Assembly (Standard Door)


See Figure 6-124 on page 6-281 and use the following procedures to remove and replace the LAD switch and cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Have the customer eject any tape cartridges occupying Row 5, Columns 12 through 22 of the access door before taking the LSM offline. 3. Push the lockcap solenoid pin down until it clears the bottom of the lockcap solenoid bracket. Press the latch CAP push bar and open the CAP. 4. Remove the two screws that attach the right-hand array in Row 10 of the access door and remove the array. 5. Disconnect the cable connector P885 from J885 at the inner door latch bracket. 6. Disconnect the two leads from the EPO contact block. 7. Disconnect P889 from J889 at the ND card. 8. Remove the two #10 nuts attaching the LAD switch to the door. 9. Remove the inner door latch subassembly by removing two flange nuts on the left side and two Torx screws on the right side. 10. Remove the two Torx screws securing the connector J885 to the inner door latch bracket. 11. Depress the ears on connector J885 and remove the bulkhead mounting plate.

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Figure 6-124. ND Card/LAD Door Switch and Cable Assembly (Standard Door)

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Replacement
1. Depress the ears on connector J885, and attach the bulkhead mounting plate previously removed. 2. Attach connector J885 bulkhead mounting plate to the inner door latch bracket using the two Torx screws previously removed. 3. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Attach the inner door latch bracket to the door using the two Torx screws on the right-hand side and the two flange nuts on the left-hand side. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Connect the two leads to the EPO contact block. 7. Connect P889 to J889 at the ND card. 8. Attach the LAD switch mounting plate to the door using the two nuts previously removed. 9. Tighten the nuts to a torque of 3 Nm (26 in.-lb). 10. Connect P885 to J885. 11. Attach the array with two screws. 12. Tighten the screws to a torque of 3 Nm (26 in.-lb). 13. Close the CAP door. 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

ND CardOptional Door
See Figure 6-126 on page 6-288 and use the following procedures to remove and replace the ND card located on the library side of the access door.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Disconnect P889 from J889 on the ND card. 4. Remove the two #6 Torx screws attaching the ND card.

Replacement
1. Attach the ND card with the two Torx screws. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb).

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3. Connect P889 to J889. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

MW CardOptional Door
See Figure 6-125 on page 6-284 and use the following procedures to remove and replace the MW card located at the top of the optional access door.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Remove the three screws attaching the MW card cover to the applicable MW card. 4. Disconnect P903-x, P908-x, and P909-x from the MW card. 5. Remove the four screws attaching the MW card to the CAP door.

Replacement
1. Attach the MW card to the CAP door using the four screws previously removed. 2. Tighten the screws to a torque of 0.95 Nm (8 in.-lb). 3. Connect P903-x, P908-x, and P909-x to the MW card. 4. Attach the MW card cover to the CAP door using the three screws previously removed. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-125. MW, MZ, and Display Card (Optional Door)

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MZ CardOptional Door
See Figure 6-125 on page 6-284 and use the following procedures to remove and replace the MZ card.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Remove the four screws attaching the MZ card cover to the CAP door. 4. Disconnect P900, P901, P902, P905, P907, P910, and P920 from the MZ card. 5. Remove the five screws attaching the MZ card to the CAP door. The lower right-hand screw has a washer. 6. Keep the screws and washer for mounting the replacement card.

Replacement
CAUTION: Component damage: There must be a washer installed on the lower right-hand screw attaching the MZ card to the door. This prevents damage to the foil at the bottom of the card. 1. Attach the MZ card to the CAP door using the five screws and washer previously removed. 2. Insert the screw with the washer through the terminal ring on the end of the display panel cable, then into the lower right-hand mounting hole to protect the card ground strap. 3. Tighten the screws to a torque to 0.9 Nm (8 in.-lb). 4. Connect P900, P901, P902, P905, P907, P910, and P920 to the MZ card. 5. Attach the MZ card cover to the CAP door using the four screws previously removed. 6. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Display PanelOptional Door


See Figure 6-125 on page 6-284 and use the following procedures to remove and replace the planar display panel. If your machine has a cherry display panel that is mounted on studs, call your local field representative for replacement information. If your machine has a cherry display panel that is not mounted on studs, order PN 4110759xx to replace the panel with a planar display panel.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Remove the four screws attaching the MZ card cover to the CAP door. 4. Note the way the ribbon cables are folded away from the heat sink, and then cut the tie wrap (if present) securing the J3 and J0 ribbon cables. 5. Disconnect J0 from the display panel. 6. Remove the nut and washer securing the terminal ring on the J0 end of the display cable. 7. Save this nut and washer. 8. Remove the four screws attaching the display panel to the spacer bars, and remove the display panel.

Replacement
1. Attach the display panel to the spacer bars with four screws. 2. Connect J0 to the display panel. 3. Fold J3 and J0 away from the heat sink. If J3 and J0 are the old-style connectors (slip-on, not locking), attach a new tie wrap in place of the one you removed earlier in Step 4. If J3 and J0 are new-style (locking) connectors, do not replace the tie wrap you previously cut.

4. Attach the terminal ring on the J0 end of the display cable to the threaded stud on the door frame. 5. Secure with the nut and washer removed previously. 6. Attach the MZ card cover to the door using four screws. 7. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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LAD Switch and Cable Assembly (Optional Door)


See Figure 6-126 on page 6-288 and use the following procedures to remove and replace the LAD switch and cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Disconnect the cable connector P885 from J885 at the inner door latch bracket. 3. Disconnect the two leads from the EPO contact block. 4. Disconnect P889 from J889 at the ND card. 5. Remove the two #10 nuts attaching the LAD switch to the door. 6. Remove the inner door latch subassembly by removing two flange nuts on the left side and two Torx screws on the right side. 7. Remove the two Torx screws securing the connector J885 to the inner door latch bracket. 8. Depress the ears on connector J885, and remove the bulkhead mounting plate.

Replacement
1. Depress the ears on connector J885, and attach the bulkhead mounting plate previously removed. 2. Attach connector J885 bulkhead mounting plate to the inner door latch bracket using the two Torx screws previously removed. 3. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Attach the inner door latch bracket to the door using the two Torx screws on the right-hand side and the two flange nuts on the left-hand side. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Connect the two leads to the EPO contact block. 7. Connect P889 to J889 at the ND card. 8. Attach the LAD switch mounting plate to the door using the two nuts previously removed. 9. Tighten the nuts to a torque of 3 Nm (26 in.-lb). 10. Connect P885 to J885. 11. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-126. ND Card/LAD Door Switch and Cable Assembly (Optional Door)

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LAD Switch (LAD Switch Assembly, Header)


See Figure 6-127 on page 6-290 and use the following procedures to remove and replace the LAD switch.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the header cover by removing eight #10 screws. 3. Remove two #10 Torx screws from the back of the header to remove the LAD switch assembly from the header. 4. Disconnect cables N/O 3, COM 3, and N/C 3 from the assembly. 5. Note the orientation of the switch, then press the ears and remove the switch from the bracket.

Replacement
1. Press the ears of the switch, and attach it to the bracket in the correct orientation. 2. Attach the three cables to the assembly. 3. Attach the assembly to the header with two #10 Torx screws. 4. Tighten the screws to a torque of 3 Nm (26 in.-lb). 5. Attach the header cover with eight #10 screws. 6. Tighten the screws to a torque of 3 Nm (26 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-127. LAD Switch Assembly, Header

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Door Latch Switch Assembly


See Figure 6-128 on page 6-292 and use the following procedures to remove and replace the door latch switch assembly located on the top of the LSM access door frame.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove eight Torx screws from the header cover and put the cover aside. 3. Remove the two Torx screws attaching the door latch switch assembly to the rear of the door frame header. 4. Disconnect cable connector P805-ADS from the door latch switch connector J805. 5. Remove the switch assembly from the header.

Replacement
1. Attach the door latch switch assembly with two screws to the rear of the door frame. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Connect cable connector P805-ADS and to the switch connector J805. 4. Check the position of the assembly by closing the access door. There is an audible sound when the door rod actuates the latch. If not, loosen the two screws and slide the assembly up or down and close the door again until the sound is heard. 5. Replace the header cover with the eight screws removed in Step 2 of the removal procedure. 6. Tighten the screws to a torque of 3 Nm (26 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-128. Door Latch Switch Assembly

DOOR LATCH SWITCH ASSEMBLY (REF)

DOOR FRAME HEADER TORX SCREW (REF)

DOOR FRAME HEADER

J805 P805

DETAIL A

DOOR FRAME HEADER (REF)

TORX SCREW (2X) TORX SCREW (8X) HEADER COVER

DOOR LATCH SWITCH ASSEMBLY

VIEW A
C28312

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Door Latch (Compression) Spring


See Figure 6-129 on page 6-294 and use the following procedures to remove and replace the door latch spring located on the access door.

Removal
1. See LSM Entry Procedure on page xliv. 2. If working on the standard door, open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. 3. Press the latch CAP push bar. 4. Disconnect the cable connector P885 from J885 at the inner door latch bracket. 5. Remove the two Torx screws securing the connector J885 to the inner door latch bracket. 6. Remove the inner door latch subassembly by removing two flange nuts on the left side and two Torx screws on the right side. 7. Disconnect two leads from the EPO contact block. 8. Compress the spring using a screwdriver until it is free of the upper latch rod arm. 9. Remove the spring from the lower latch rod.

Replacement
1. Compress the spring and release it between the upper and lower latch rods. 2. Hold the inner door latch subassembly, and connect the two leads to the EPO contact block terminals. 3. Attach the inner door latch subassembly by threading and tightening two Torx screws on the right side and two flange nuts on the left side. 4. Attach the connector J885 plate to the bracket with the two Torx screws previously removed. 5. Connect cable connector P885 to J885. 6. Close the CAP door (on standard door). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-129. Door Latch (Compression) Spring

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Interlock SwitchHeader Assembly


See Figure 6-130 on page 6-296 and use the following procedures to remove and replace the switch (RE override or theta backup) located in the header interlock switch assembly on the top of the LSM access door frame.

Removal
1. See LSM Entry Procedure on page xliv. 2. Set the DC power switch to OFF on the LCU. 3. Remove eight Torx screws from the header cover, and put the cover aside. 4. Loosen the two Torx screws at the bottom of the assembly. 5. While supporting the assembly, remove the two Torx screws and washer plate from the back of the door frame header. 6. Remove two Torx screws from the bottom of the door interlock bracket to separate the two brackets. 7. Disconnect the leads from the defective switch. Ensure the leads are labeled as they are removed from the switch. 8. Press the ears on the switch, and pull it out through the door interlock mounting bracket. 9. If the override switch is being replaced, remove the actuator from the switch by removing the O ring/actuator/O ring and pulling it away.

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Figure 6-130. Header Assembly Interlock Switch

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Replacement
1. If the override switch is being replaced, attach the actuator to the new switch with the O ring/actuator/O ring previously removed. 2. Press the ears on the switch (override or theta backup), and push it through the interlock mounting bracket. 3. Connect the interlock switches cable connectors to the respective switch terminals. 4. Connect the door interlock bracket and interlock mounting bracket with two Torx screws. 5. Move the interlock mounting bracket to the rear of the door interlock bracket, and leave the screws loose. 6. Attach the assembly and washer plate at the rear of the door frame header with two Torx screws, leaving the two screws loose for alignment. 7. Center the holes in the assembly with the two studs on the access door as the access door is closed and latched by someone outside the LSM. 8. Tighten the two screws in the rear of the header washer plate to a torque of 3 Nm (26 in.-lb) while maintaining this alignment. 9. Move the interlock mounting plate forward until the switches actuate (producing a clicking sound). 10. Tighten the two screws in the bottom of the assembly to a torque of 3 Nm (26 in.-lb) while maintaining this condition. 11. Check the alignment by opening and closing the door. The studs on the access door should fit into the assembly, by depressing the interlock switches and producing a clicking sound. If you do not hear a sound, loosen the bottom Torx screws, and move the assembly in or out and retry until you hear the click. 12. Replace the header cover with the eight screws previously removed. 13. Tighten the screws to a torque of 3 Nm (26 in.-lb). 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Door Interlock Switch SubassemblyHinge


See Figure 6-131 on page 6--299 and use the following procedure to remove and replace the interlock switch assembly located on the door interlock switch subassembly attached to the cartridge drive (CD) wall air box.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the four screws from the interlock switch cover. 3. Trace the mounting bracket of the door interlock switch subassembly with a scribe for easy reinstallation. 4. Remove the two Torx screws on the mounting bracket with an offset Torx screwdriver. CAUTION: Component damage: Do not use too much pressure or the interlock switch could be damaged. 5. Slide out the door interlock switch subassembly. 6. Disconnect J805 from P805. 7. Unplug the lugs from the interlock switch, noting their position and the caution below. 8. Press the ears of the LSM interlock switch with pliers, and pull the switch out of the hole in the mounting bracket.

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Figure 6-131. Hinge Interlock Switch


INTERLOCK SWITCHES CABLE ASSEMBLY (REF) DOOR FRAME HEADER

INTERLOCK MOUNTING BRACKET

EAR

ACTUATOR

A TO LAD SWITCH

OPEN CONTACT LEAD SWITCH (2X)

O RINGS

TORX SCREW (2X) WASHER PLATE

DOOR INTERLOCK BRACKET

TORX SCREW (REF)

INTERLOCK SWITCH ASSEMBLY DETAIL A


DOOR FRAME HEADER (REF)

TORX SCREW (2X) TORX SCREW (8X) HEADER COVER

INTERLOCK SWITCH ASSEMBLY

VIEW A
C28314

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Replacement
1. Press the ears of the LSM interlock switch with pliers and push the switch through the hole in the mounting bracket. COMMON (written on the switch) should be to the top of the mounting bracket. CAUTION: Component damage: See Figure 6-131 on page 6-299 for the next step. The lead connectors must be attached to the correct terminal on the switch. The switch terminals and corresponding leads are marked and should be connected as follows: Lead Number 1 connects to OPEN terminal, 2 to COMMON, and 3 to CLOSED. 2. Plug the lugs into the interlock switch as noted previously. 3. Connect J805 and P805. 4. Attach the door interlock switch subassembly to the CD wall air box with the two Torx screws, using the tracing as a guide. The Torx screws should be in the center of the slots. CAUTION: Component damage: Do not use too much pressure or the interlock switch could be damaged. 5. Attach the interlock switch cover to the CD wall air box with four screws. 6. Tighten the screws to a torque of 3 Nm (26 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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EPO Contact Block


See Figure 6-132 on page 6-302 and use the following procedures to remove and replace the EPO contact block located on the access door.

Removal
1. See LSM Entry Procedure on page xliv. 2. Set the LCU DC power switch to OFF. 3. Open the CAP door. 4. Disconnect cable connector P885 from connector J885 on the inner door latch subassembly. 5. Remove the inner door latch subassembly from the door by removing the two flange nuts from the left-hand side and the two Torx screws from the right-hand side of the bracket. 6. Remove the two Torx screws securing J885 to the inner door latch bracket. 7. Remove the two lead connectors from the EPO contact block terminals. 8. Grasp the rear portion of the EPO actuator that has the contact block mounted on it, and apply force to one side to release from the front portion. 9. With a small common screwdriver, gently pry the ears of the contact block out of the locking grooves of the rear actuator portion. Doing this releases the EPO actuator and contact block.

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Figure 6-132. EPO Contact Block

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Replacement
1. Snap the EPO contact block onto the rear EPO actuator portion. 2. Attach the rear portion of the actuator to the front portion by positioning the terminals of the contact block toward the bottom of the inner door latch bracket, aligning the two portions of the actuator and snapping them together until they lock. 3. Hold the inner door latch subassembly in place, and connect the two leads to the contact block terminals. 4. Attach the connector J885 plate to the bracket using the two screws previously removed. 5. Attach the inner door latch subassembly to the door using the two nuts and two screws previously removed. 6. Connect cable connector P885 to J885 on the subassembly. 7. Close the CAP. 8. Test the EPO circuit using the access door EPO switch and the procedure in EPO Switches in Chapter 3, Maintenance Procedures. 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Safety Door Springs (21-Cell CAP Only)


See Figure 6-133 on page 6-304 and use the following procedures to remove and replace the safety door springs located in the torque adjusters.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. Press the latch CAP push bar. 3. For the older type hinge, remove the retaining ring from the groove in the bottom of the torque adjuster. 4. Remove the two nuts from the hinge support and remove the support. 5. Pull the bearing and the spring from the torque adjuster. 6. Retain the bearing.

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Figure 6-133. Safety Door Spring (21-Cell CAP)

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Replacement
1. Insert the new spring up into the torque adjuster, aligning the top groove. Insert the bearing under the spring. For the older type hinge, insert the retaining ring into the groove on the bottom of the torque adjuster. 2. Attach the hinge support to the safety door with two nuts. 3. Adjust the torque adjuster in the hinge supports one turn to provide the proper tension on the safety door, using the following procedure: a. Remove the socket head screw from each torque adjuster.

b. Use two #6 screws or center punches to turn the torque adjuster clockwise one turn. If the older type hinge support is installed, hold the torque adjuster in this position and have someone from outside the access door insert the socket head screw into the threaded hole just clockwise of the CAP hinge block. Leave the screw approximately 6.35 mm (0.25 in.) out of the torque adjuster. This portion of the screw rests against the access door surface when the torque adjuster is released, providing the proper spring tension. If the newer type hinge support is installed, insert the socket head cap screw through the hole in the top of the hinge support and thread it into the torque adjuster. Leave the screw approximately 3.18 mm (1/8-in.) out of the torque adjuster. c. Close the CAP.

d. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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CAP Locked Solenoid Cable Assembly (21-Cell CAP)


See Figure 6-134 on page 6-307 and use the following procedures to remove and replace the CAP lock solenoid located on the standard access door. Note: This solenoid can only be used on the CAP locked solenoid subassembly having a proximity sensor. If the subassembly has an NV card instead of a proximity sensor, the solenoid is not a FRU (replace the CAP solenoid lock assembly).

Removal
1. Have the customer move or eject the tape cartridges in Rows 8 and 9 of the access door before varying the LSM offline. 2. See LSM Entry Procedure on page xliv. 3. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. Press the latch CAP push bar. 4. Remove cartridge arrays in Rows 8 and 9 by removing two screws per array. 5. Disconnect cable connector P875 from the solenoid connector J875. 6. Remove the two screws attaching the CAP lock solenoid to the bracket. 7. Pull the solenoid out from the side of the bracket.

Replacement
1. Slide the solenoid through the side of the bracket into mounting position (short shaft of the solenoid at the top) and secure with two screws. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Connect P875 to J875. 4. Attach Arrays 8 and 9 with two screws each. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Close the CAP. 7. Check for a 1.6 mm (1/16 in.) clearance between the lockcap solenoid bracket and the CAP lock solenoid bracket. Adjust, if necessary. 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-134. CAP Solenoid and Door Locked Switch (21-Cell CAP)

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CAP Solenoid Lock Assembly (21-Cell CAP)


See Figure 6-135 on page 6-310 and use the following procedures to remove and replace the CAP solenoid lock assembly on the standard access door. Note: On initial upgrade to this FRU, a companion part is required. Refer to the Library Storage Module Compatibility Manual, PN 4902, for compatibility information.

Removal
1. Have the customer move or eject the tape cartridges in Rows 8 and 9 of the access door before varying the LSM offline. 2. See LSM Entry Procedure on page xliv. 3. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. Press the latch CAP push bar. 4. Remove the cartridges arrays in Rows 8 and 9 by removing the two screws per array. 5. Disconnect P875 from the solenoid connector J875. 6. Disconnect cable connector P878 from J878 on the NV card (or proximity switch if this an initial upgrade). 7. Disconnect the two spade lugs (NC and COM) from the CAP door locked switch. Ensure that the leads are labeled as to switch terminal location. 8. Remove the two 10-32 flange nuts attaching the subassembly to the door. Retain the nuts for later use. 9. If this is an initial upgrade, remove the two 10-32 flange nuts attaching the CAP lock bracket to the CAP (Figure 6-148 on page 6-346). 10. Keep the two nuts.

Replacement
1. Verify the CAP is adjusted for a clearance of 1.27 mm (0.050 in.) between the bottom of the CAP and the top of the lower decorative cover on the access door. Align the CAP horizontally so that the sides of the CAP panel align with the sides of the lower decorative access door cover. 2. If this is an initial upgrade, attach the CAP lock bracket (companion part) to the CAP using the two nuts removed from the old bracket. 3. Adjust the bracket vertically so the space between the bottom of the bracket and door (as the CAP is closed) is also 1.27 mm (0.050 in). Move the bracket until the bottom edge is parallel to the CAP opening in the door while maintaining this spacing. 4. Tighten the two nuts to a torque of 5 to 7 Nm (45 to 60 in.-lb).

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5. Attach the replacement CAP solenoid lock assembly to the access door using the two 10-32 nuts previously removed. 6. Verify the safety door is adjusted properly (equal gap between the cam arms and cam follower tracks at top and bottom). 7. Adjust the CAP solenoid bracket assembly vertically until the bottom edge of the safety door is 1.27 mm (0.050 in.) above the CAP flag roller. 8. Verify the alignment of the CAP solenoid lock to the hole in the CAP lock bracket. Slight movement of the assembly for vertical and horizontal alignment is possible. 9. Tighten the nuts to a torque of 5 to 7 Nm (45 to 60 in.-lb). 10. Connect P878 to J878 on the NV card. 11. Connect P875 to solenoid connector J875. 12. Connect the two spade lugs (NC and COM) to their respective connector terminals on the CAP door locked switch. 13. Secure any wires that may interfere with CAP or robot operation. 14. Close the CAP, and verify that the flag is raised out of the sensor on the NV card, does not interfere with the safety door, and the solenoid lock can be moved upward, by hand, into the hole of the lock bracket without binding. 15. Attach Arrays 8 and 9 with two screws each. 16. Tighten the screws to a torque of 3 Nm (26 in.-lb). 17. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-135. CAP Solenoid Lock Assembly (21-Cell CAP)

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CAP Door Latch Sensor (21-Cell CAP)


See Figure 6-136 on page 6-312 and use the following procedures to remove and replace the CAP door latch optical sensor cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. 3. Press the latch CAP push bar. 4. Remove Array 5 on the left side of the door by removing the two screws attaching it to the door. 5. Remove two 4-40 nuts, lock washers, and screws holding the sensor. 6. Disconnect P1-CAP. 7. Remove the cable tie.

Replacement
1. Connect P1-CAP. 2. Attach the cable tie. 3. Install the sensor to the bracket with two Torx screws, lock washers, and nuts. 4. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 5. Attach Array 5 to the door with two screws. 6. Tighten the screws to a torque of 3 Nm (26 in.-lb). 7. Close the CAP. 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-136. CAP Optical Sensor Cable Assembly (21-Cell CAP)

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CAP Latch Sensor Bracket Assembly (21-Cell CAP)


See Figure 6-136 on page 6-312 and use the following procedures to remove and replace the CAP door latch sensor bracket assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. Press the latch CAP push bar. 3. Remove the hardware attaching the sensor cable assembly to the latch bracket assembly. Note: Earlier version brackets use two screws and lock washers. The newer version uses two screws, two washers, and two nuts. 4. Remove the two 10-32 nuts attaching the latch bracket to the access door. 5. If this is an initial upgrade to this FRU, a companion part (a CAP latch) is required. Refer to the Library Storage Module Compatibility Manual, PN 4902 for information. Use the removal procedure in CAP LatchStandard Door on page 6-345 to remove the CAP latch.

Replacement
1. Attach the CAP latch sensor bracket assembly to the access door using the two 10-32 nuts previously removed. 2. If this is an initial upgrade to this FRU, see the replacement procedure in CAP LatchStandard Door on page 6-345. 3. Install the sensor to the bracket with the two Torx screws, lock washers, and nuts. 4. Tighten the nuts to a torque of 3 Nm (26 in.-lb). 5. Open and close the CAP to verify that the latch operates the flag on the CAP door open sensor properly. 6. With the CAP closed and the latch completely engaged, the flag should be positioned with the 1/4-in. sensor hole displaced completely from the sensor, but the flag stop pin should not be tight against the flag stop. 7. If the condition described in the previous step is not met, readjust the assembly slightly left or right until the condition is met. Adjustment can be made with the CAP closed so that the flag position can be monitored while adjusting (this might require removal of an array). 8. Tighten the two screws to a torque of 3 Nm (26 in.-lb). 9. Close the CAP.

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10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

CAP Door Locked Switch (21-Cell CAP)


See Figure 6-134 on page 6-307 or Figure 6-135 on page 6-310 and use the following procedures to remove and replace the CAP door locked switch, which is located on the standard access door below the CAP lock solenoid. Note: This switch is a FRU for two different CAP locked brackets. For the brackets having a proximity switch attached, the solenoid and switch can be removed without removing the bracket from the access door. On the brackets having an NV card attached, the bracket must be removed from the access door to remove the solenoid and switch. The solenoid on both must be removed before the CAP locked switch can be removed.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. 3. Press the latch CAP push bar. 4. On the assembly having a proximity switch attached: a. Remove the two Torx-head screws securing the CAP locked solenoid to the bracket.

b. Slide the solenoid out of the left-hand side of the bracket. c. Ensure the leads connected to the CAP door locked switch are labeled.

d. Disconnect the two leads (N/C and COM) from the CAP door locked switch. e. Compress the ears of the switch and push it up through the bracket to remove from either side.

5. On the assembly having an NV card attached: a. Remove cartridge arrays in Rows 8 and 9 by removing two screws per array.

b. Disconnect P875 from the solenoid connector J875. c. Disconnect P878 from J878 on the NV card.

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d. Disconnect the two spade lugs (NC and COM) from the CAP door locked switch. Ensure that the leads are labeled as to switch terminal location. e. f. Remove the two 10-32 flange nuts attaching the subassembly to the door. Remove the two screws from the back of the bracket attaching the solenoid. Be careful not to drop the lock pin off the solenoid shaft as it is removed. Compress the ears of the switch and push it up through the bracket to remove it.

g.

Replacement
1. Compress the ears of the switch and slide it down into the CAP lock solenoid bracket with the common and N/C terminals facing the right-hand side of the bracket. 2. On the assembly having a proximity switch: a. Connect the two leads to the respective terminals of the switch.

b. Slide the solenoid through the side of the bracket and secure with two screws. c. Tighten the screws to a torque of 3 Nm (26 in.-lb).

3. On the assembly having an NV card attached: a. Place the lock pin onto the long shaft of the solenoid and insert the pin into the bracket.

b. Attach the solenoid to the bracket using the two screws previously removed c. Tighten the screws to a torque of 3 Nm (26 in.-lb).

d. Attach the CAP solenoid lock assembly to the access door using the two 10-32 nuts previously removed. e. f. Adjust the assembly vertically until the bottom edge of the safety door is 1.27 mm (0.050 in.) above the CAP flag roller. Verify the alignment of the CAP solenoid lock to the hole in the CAP lock bracket. Slight movement of the assembly for vertical and horizontal alignment is possible. Tighten the nuts to a torque of 3 Nm (26 in.-lb).

g.

h. Connect P878 to J878 on the NV card. i. Connect P875 to solenoid connector J875.

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j.

Connect the two spade lugs (NC and COM) to their respective connector terminals on the CAP door locked switch.

k. Secure any wires that may interfere with CAP or robot operation. Close the CAP, and verify that the flag is raised out of the sensor on the NV card does not interfere with the safety door and the solenoid lock can be moved upward, by hand, into the hole of the lock bracket without binding. l. Attach Arrays 8 and 9 with two screws each.

m. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

NA CardOperator Panel (21- Cell CAP)


See Figure 6-137 on page 6-317 and use the following procedures to remove and replace the NA card located on the access door, behind the operator panel and above the CAP.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Disconnect P880 from J880. 4. Remove the two Torx screws attaching the card to the door.

Replacement
1. Attach the NA card to the door with two Torx screws. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Connect P880 to J880. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-137. NA Card (21-Cell CAP)

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Access Door Cable Assembly (Standard Door)


See Figure 6-138 on page 6-319 and use the following procedures to remove and replace the cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove Arrays 0 through 9 from the left side of the door by removing two screws per array. 3. Cut the appropriate cable ties and disconnect the following plugs and leads from the door and CD wall, starting at the upper left side of the access door: P870 (header to LCU), P880 (NA card) P1-CAP (optical sensor cable assembly) P875-CDL (CAP locked solenoid) SW807 (CAP locked switch assembly) P876 (CAP door open proximity switch) P885 (bulkhead connector)

Replacement
1. Attach new cable ties where the old ones were removed. 2. Position the new cable assembly where the old one was positioned. 3. Connect the plugs and switch disconnected above and attach the cable ties. 4. Attach Arrays 0 through 9 to the left side of the door by threading and tightening two screws per array. 5. Tighten the screws to a torque of 3 Nm (26 in.-lb). 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-138. Standard Access Door Cable Assembly

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Access Door/MZ Card, ME8 Harness (Optional Door)


See Figure 6-139 on page 6-321 and Figure 6-140 on page 6-322 and use the following procedures to remove and replace the harness.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Remove the four screws attaching the MZ card cover to the access door. 4. Cut the 18-in. cable tie securing the excess cables in the cable retainer. 5. Disconnect P/J870 near the upper door hinge. 6. Cut the appropriate cable ties to free the harness from the other two. 7. Remove the cable duct cover that is mounted vertically on the access door between CAP 1 and the MZ card/PCAP. 8. Disconnect J902 from the MZ card. 9. Disconnect J931 (above the PCAP). 10. Depress the ears on connector J931 and remove the connector from the door. 11. Disconnect P885 at the inner door latch bracket. 12. Remove the cable from the door by feeding it through the cable cutout at the top of the door.

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Figure 6-139. Optional Access Door Cables (Sheet 1 of 2)

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Figure 6-140. Optional Access Door Cables (Sheet 2 of 2)

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Replacement
1. Route the cable starting at the inner door latch moving upward through the cable duct and routing under the shelf and out through the cable cutout at the top of the door. Connector P870 should be positioned near the upper door hinge. 2. Connect J902 to the MZ card. 3. Compress the ears of connector J931 and insert the connector into the door above the PCAP. 4. Connect P931 to J931. 5. Connect P885 to J885 on the inner door latch bracket. 6. Place the cables of the harness into the cable duct and install the cover on the duct. 7. Connect P870 to J870 at the hinged CD wall. 8. With the door open, place any excess cable into the cable retainer located on the CD wall air box. 9. Secure with an 18-in. cable tie. Note: Both pieces of the cable tie should be in front of the cables. 10. Attach the three cables coming from the access door together using two cable ties equally spaced from retainer to cable cutout in the door. 11. Attach the MZ card cover to the door using the four screws previously removed. 12. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 13. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Hinge, CAP 1/0-MW 0/1 Harness (Optional Door)


See Figure 6-139 on page 6-321 and Figure 6-140 on page 6-322 and use the following procedures to remove and replace the harness.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Open both CAPs (see Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349).

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a.

Remove the second magazine from the top from the CAP.

b. Locate the access hole adjacent to the CAP door latch. c. Insert a common-blade screwdriver through the hole, and locate the space between the solenoid and solenoid latch bar.

d. Apply pressure against the latch bar to unlock the solenoid. 4. Remove the four screws attaching the MZ card cover to the access door. 5. Remove the three screws attaching both MW card covers to the door. 6. Disconnect P910 from the MZ card. 7. Disconnect P908-0 and P908-1 from the MW cards. 8. Remove the cover from the cable duct mounted vertically on the access door between CAP 1 and the MZ card/PCAP. 9. Cut the cable ties securing the cables (two) to each CAP door closed sensor bracket and the cable tie on the mount at the bottom of the door (to the right of the bottom of CAP 1). 10. Remove the four screws attaching the strain reliefs on each cable going to the two CAPs (J919-0 and J919-1). 11. Disconnect J919-100 and J919-101 at the two CAPs. 12. Remove the harness assembly from the door.

Replacement
1. Connect J908-0 and J908-1 to the respective MW cards. 2. Connect J910 to the MZ card. 3. Route the harness down through the cable duct to the bottom of the door, underneath past the CAP door closed sensor brackets and up to the respective CAP connectors P919. 4. Connect J919-100 to CAP 0. 5. Connect J919-101 to CAP 1. 6. Attach the four strain reliefs on the two CAP cables using the four screws previously removed. 7. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 8. Secure the cables along with the existing MZ cable assembly to the door cable tie mount and to each of the CAP door closed sensor brackets with cable ties. 9. Install the cable duct cover over the cables. 10. Attach the MZ card cover using the four screws previously removed.

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11. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 12. Attach the two MW card covers to the door using the six screws previously removed. 13. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

DC Power, MZ Card Cable Assembly (Optional Door)


See Figure 6-139 on page 6-321 and Figure 6-140 on page 6-322 and use the following procedures to remove and replace the cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Remove the four screws attaching the MZ card cover to the access door. 4. Cut the 18-in. cable tie securing the excess cables in the cable retainer. 5. Disconnect P/J925 near the upper door hinge. 6. Cut the appropriate cable ties to free the harness from the other two. 7. Disconnect P901 from the MZ card. 8. Remove the cable assembly from under the door shelf and out of the cable cutout.

Replacement
1. Route the cable under the shelf at the top of the door, out of the cable cutout and over to the CD wall. 2. Connect P925 to J925. 3. Connect P901 to the MZ card. 4. With the door open, place any excess cable into the cable retainer located on the CD wall air box. Secure with an 18-in. cable tie. Note: Both pieces of the cable tie should be in front of the cables. 5. Attach the three cables coming from the access door together using two cable ties equally spaced from retainer to cable cutout in the door. 6. Attach the MZ card cover to the door using the four screws previously removed. 7. Tighten the screws to a torque of 1.4 Nm (12 in.-lb).

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8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

MW to CAP Cable Assembly (Optional Door)


See Figure 6-139 on page 6-321 and Figure 6-140 on page 6-322 and use the following procedures to remove and replace either cable assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Open the applicable CAP (see Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349). a. Remove the second magazine from the top from the CAP.

b. Locate the access hole adjacent to the CAP door latch. c. Insert a common-blade screwdriver through the hole, and locate the space between the solenoid and solenoid latch bar.

d. Apply pressure against the latch bar to unlock the solenoid. 4. Remove the three screws attaching the affected CAPs MW card cover. 5. Disconnect P909 from the MW card. 6. Disconnect P929 from J929 on the CAP. 7. Remove the two screws attaching the cable strain reliefs on the door and CAP. 8. Remove the cable assembly.

Replacement
1. Connect P909 to the MW card. 2. Connect P929 to J929 on the CAP door. 3. Attach the two strain reliefs to the door and CAP using the screws previously removed. 4. Tighten the screws to torque of 1.4 Nm (12 in.-lb). 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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CAP Open/Close Sensor (Optional Door)


See Figure 6-141 on page 6-328 and use the following procedures to remove and replace the CAP open/close sensor assembly on the optional door.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Locate the applicable door open/close sensor assembly. The CAP 0 sensor is called ME11 and the CAP 1 sensor is ME10. 4. Disconnect P727-11x from the ME card on the assembly (P727-111 goes to ME card on CAP 0, P727-110 to CAP 1 ME card). 5. Cut the cable tie on the sensor assembly bracket that secures the cables to it. 6. Remove the three screws attaching the sensor assembly to the shelf on the access door.

Replacement
1. Attach the sensor assembly to the access door using the three screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect P727-11x to the ME card on the assembly. 4. Attach the two cables to the sensor assembly bracket using a cable tie. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-141. CAP Open/Close Sensor Assembly

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Magazine Sensor Assembly (Optional Door CAP)


See Figure 6-142 on page 6-330 and use the following procedures to remove and replace the CAP open/close sensor assembly on the optional door.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Open the applicable CAP (see Figure 6-149 on page 6-348). Note: A newer design of the CAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the CAP latch. To unlock the CAP, place a small screwdriver blade into the right hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the CAP: a. Remove the second magazine from the top from the CAP.

b. Locate the access hole adjacent to the CAP door latch. c. Insert a common-blade screwdriver through hole, and locate space between solenoid and solenoid latch bar.

d. Apply pressure against the latch bar to unlock the solenoid. 4. Remove three screws attaching the appropriate sensor harness cover. The sensors are referenced as ME0 through ME3 from top to bottom on CAP 0. For CAP 1, they are ME4 through ME7 from top to bottom. The sensor harness cover for ME0, ME1, ME4, and ME5 is the top cover on CAP 0 and CAP 1 respectively. The bottom sensor harness cover is for ME2, ME3, ME6, and ME7 on CAP 0 and CAP 1 respectively.

5. Disconnect P727-10x from the ME card on the assembly. 6. Remove three screws attaching sensor assembly to CAP door.

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Figure 6-142. Magazine SensorsCAP

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Replacement
1. Attach the sensor assembly to the CAP door using the three screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect P727-10x to the ME card on the assembly. 4. Attach the sensor harness cover to the CAP door using the three screws previously removed. Do not pin the cable with the cover. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

PCAP Open/Close Sensor AssemblyOptional Door


This sensor is referenced as ME9. See Figure 6-143 on page 6-333 and use the following procedures to remove and replace the CAP open/close sensor assembly on the optional door.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Open the PCAP (see Figure 6-143 on page 6-333). Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. To unlock the PCAP, place a small screwdriver blade into the left hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the PCAP. a. Insert a 3-in. common-blade screwdriver down through the access hole in the top of the PCAP latch cover.

b. Position the blade in the space between the end of the solenoid and the solenoid latch bar. c. Apply force against the latch bar to unlock the solenoid. Then open the PCAP using the latch handle.

4. Disconnect P727-109 from the ME card on the assembly. 5. Remove the cable tie attaching cable to PCAP bracket assembly. 6. Remove the three screws attaching the sensor assembly to the PCAP bracket assembly.

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Replacement
1. Attach the sensor assembly to the PCAP bracket assembly using the three screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect P727-109 to the ME card on the assembly. 4. Attach cable to PCAP bracket assembly using a cable tie. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-143. PCAP Open/Closed Sensor

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Cam Followers21-Cell CAP Safety Door


Use the following procedure to remove and replace the two cam followers located on the left side of the safety door.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove four screws each from the top and bottom cam plates, and pull the plates out. 3. Unscrew the cam followers from the safety door.

Replacement
1. Thread and tighten the cam followers into the safety door. 2. Thread and tighten the four screws on the top cam plate and four screws on the bottom cam plate. 3. Tighten the screws to a torque of 3 Nm (26 in.-lb). 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

Gas Spring21-Cell CAP


See Figure 6-144 on page 6-335 and Figure 6-145 on page 6-337 and use the following procedures to remove and replace the CAP gas spring located on the right side of the CAP (from inside the LSM).

Removal
1. See LSM Entry Procedure on page xliv. 2. Unsnap the clips from around the gas spring, and withdraw the clips from the holes that secure the gas spring to the ball studs. 3. Remove the gas spring from the ball studs.

Replacement
1. Place the gas spring onto the two ball studs. Note: When the gas spring is installed, the rod end of the gas spring should be lower than the cylinder end. 2. Slip the clips into the holes on the gas spring ends, and snap the clip over the gas spring. 3. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-144. Gas SpringCAP (Sheet 1 of 2)

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Gas SpringOptional Door CAP


See Figure 6-144 on page 6-335 and Figure 6-145 on page 6-337 and use the following procedures to remove and replace the CAP and PCAP gas springs. The gas springs on the two CAPs are located at the top of the CAP. The PCAP gas spring is located on the bottom of the PCAP.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the applicable CAP/PCAP. 3. Insert a small common-blade screwdriver under the locking clip in the end of the gas spring, and pry up enough to release the end from the ball stud. 4. Repeat the process for the opposite end of the gas spring.

Replacement
1. Place the gas spring over the ball stud and snap it into place. Note: When the gas spring is installed, the rod end of the gas spring should be lower than the cylinder end. 2. Repeat Step 1 for the opposite end of the gas spring. 3. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-145. Gas SpringCAP (Sheet 2 of 2)

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PCAP TrayOptional Door


The cartridge present sensor is a component part of the tray assembly. The sensor is referenced as ME8. See Figure 6-146 on page 6-339 and use the following procedures to remove and replace the PCAP tray assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the PCAP (see Figure 6-143 on page 6-333). Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. To unlock the PCAP, place a small screwdriver blade into the left hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the PCAP. a. Insert a 3-in. common-blade screwdriver down through the access hole in the top of the PCAP latch cover.

b. Position the blade in the space between the end of the solenoid and the solenoid latch bar. c. Apply force against the latch bar to unlock the solenoid. Then, open the PCAP using the latch handle.

3. Remove the four screws attaching the decorative cover to the PCAP. The cover might fit snugly and require a slight amount of prying to remove it. 4. Remove the two screws attaching the PCAP tray to the PCAP door. 5. Remove the three screws attaching the PCAP shelf to the PCAP door. 6. Remove the shelf from the door. 7. Disconnect J727-108 from the ME card on the bottom of the PCAP tray as the tray is being removed.

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Figure 6-146. PCAP Tray/HarnessOptional Door

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Replacement
1. Connect J727-108 to the ME card on the bottom of the PCAP tray. 2. Attach the PCAP tray to the PCAP door using the two screws previously removed. 3. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 4. Attach the PCAP shelf to the PCAP door using the three screws previously removed. Route the cartridge present cable (P727) through the slot in the shelf. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Attach the decorative cover to the PCAP door using the four screws previously removed. 7. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

PCAP HarnessOptional Door


See Figure 6-146 on page 6-339 and use the following procedures to remove and replace the PCAP harness.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the PCAP (see Figure 6-143 on page 6-333). Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. To unlock the PCAP, place a small screwdriver blade into the left hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the PCAP. a. Insert a 3-in. common-blade screwdriver down through the access hole in the top of the PCAP latch cover.

b. Position the blade in the space between the end of the solenoid and the solenoid latch bar. c. Apply force against the latch bar to unlock the solenoid. Then open the PCAP using the latch handle.

3. Remove four screws attaching the decorative cover to the PCAP. The cover might fit snugly and require a slight amount of prying to remove it. 4. Remove two screws attaching the PCAP tray to the PCAP door.

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5. Remove three screws attaching the PCAP shelf to the PCAP door. 6. Remove the shelf from the door. 7. Disconnect J727 to the ME card on the bottom of the PCAP tray as the tray is being removed. 8. Disconnect P/J875 and P/J930 (in the PCAP door) and P/J931 (above the PCAP on the right-hand side). 9. Remove the two screws attaching the cable strain reliefs to the PCAP door and the access door. 10. Remove the harness from the PCAP door.

Replacement
1. Route the harness inside the PCAP door with P875, J727, and P930 inside. 2. Connect P/J875, P/J930, and J727 to the ME card (on the PCAP tray). 3. Connect P/J931 above the PCAP (right-hand side of PCAP). 4. Attach the harness strain reliefs to the PCAP door, and access door using the two screws previously removed. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Attach the PCAP tray to the PCAP door using the two screws previously removed. 7. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 8. Attach the PCAP shelf to the PCAP door using the three screws previously removed. Route the cartridge present cable (P727) through the slot in the shelf. 9. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 10. Attach the decorative cover to the PCAP door using the four screws previously removed. 11. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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HBO Sensor/Switch AssemblyDoor


See Figure 6-147 on page 6-344 and use the following procedures to remove and replace the HBO sensor assembly located on the top of the LSM access door frame.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove eight Torx screws from the header cover, and put the screws and cover aside. If the HBO sensor/switch is an old-style, mechanical sensor (PN 4102707xx), disconnect J875 and J1 from P875 and P1. If the HBO sensor/switch is a new-style, electronic sensor (PN 4110857), disconnect P804 from J804 on the MG card.

3. Remove the three screws holding the HBO assembly to the door frame header and remove the assembly.

Replacement
Note: Regardless of the type of HBO sensor that you just removed, your replacement HBO sensor is an electronic sensor. Furthermore if the MG card in your LSM is an old-style card (4-connector, PN 4101800xx), you must replace it with a new-style MG card (7connector, PN 4110480xx). See the replacement procedure in LSM Interlock Card (MG Card) on page 6-98. 1. Assemble the new HBO switch assembly into the door frame header by depressing the switch lever and guiding the lever plunger through the hole in the header. Install three Torx screws, and leave them only finger-tight so that the assembly can still be moved to adjust it. Note: The plunger does not move straight in and out of the hole in the header when it is actuated. Because of this, the assembly must be adjusted to ensure proper operation. 2. Move the assembly until the plunger operates freely over its full range of travel and does not touch the side of the hole in the header (this is a concern mainly with older door frames that have smaller plunger holes, machines with serial numbers of approximately 1500 and earlier). 3. Tighten the screws on the sensor to a torque of 3 Nm (26 in.-lb). 4. If you have to replace the MG card, do so at this time. Go to LSM Interlock Card (MG Card) on page 6-98, begin at Step 4 of the removal procedure, and continue through Step 2 of the replacement procedure. If you are not replacing the MG card, continue with Step 5.

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5. Connect P804 to J804 on the MG card. 6. Make sure that no wires interfere with the switch mechanism and that no wires are pinned. 7. Replace the header cover with the eight screws removed in Step 1. 8. Tighten the screws to a torque of 3 Nm (26 in.-lb). 9. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-147. HBO Sensor Assembly

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CAP LatchStandard Door


See Figure 6-148 on page 6-346 and use the following procedures to remove and replace the CAP latch from the CAP latch push bar.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the CAP by pushing the pin down until it clears the bottom of the lockcap solenoid bracket. Press the latch CAP push bar. 3. From the CAP latch, remove the two Torx screws, lock washers, and flat washers with an offset Torx screwdriver. 4. Remove the two parts, the CAP latch push bar from the side and the CAP latch from the front. Do not remove the two springs on the CAP latch push bar dowel pins.

Replacement
Note: If the CAP latch being replaced has a sensor flag as a part of the latch, the CAP latch sensor bracket assembly must also be replaced. Refer to the Library Storage Module Compatibility Manual, PN 4902, for part number information. The CAP latch sensor bracket assembly removal and replacement procedure can be found in CAP Door Latch Sensor (21-Cell CAP) on page 6-311. 1. Put the two parts back into the latch in the same places they were. 2. Thread and tighten the two Torx screws, lock washers, and flat washers. 3. Check the position by closing the door. The EMI gasket should compress approximately halfway. If not, loosen the two screws, and move the CAP latch in or out and retry. 4. Tighten the screws to a torque of 3 Nm (26 in.-lb). 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-148. CAP LatchStandard Door

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CAP Door Latch AssemblyOptional Door


See Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349 and use the following procedures to remove and replace the CAP door latch assembly on the optional door CAPs.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the applicable CAP (see Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349). Note: A newer design of the CAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the CAP latch. To unlock the CAP, place a small screwdriver blade into the right hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the CAP. a. Remove the second magazine from the top from the CAP.

b. Locate the access hole adjacent to the CAP door latch. c. Insert a common-blade screwdriver through the hole, and locate the space between solenoid and solenoid latch bar.

3. Apply pressure against the latch bar to unlock the solenoid. 4. Remove 16 screws attaching the top, middle, and bottom decorative covers to the CAP door. 5. Remove four screws attaching the latch cover to the CAP door. 6. Remove two hairpin clips attaching the latch rod to the slam latch and door latch assembly. 7. Disconnect P/J875 and P/J930. 8. Remove the four flange nuts attaching the door latch assembly to the access door. 9. Remove the door latch assembly from the front of CAP door.

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Figure 6-149. CAP Latch SystemOptional Door (Sheet 1 of 2)

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Figure 6-150. CAP Latch SystemOptional Door (Sheet 2 of 2)

Replacement
1. Insert the cables with J930 and J875 and the door latch assembly into the opening in the CAP door. 2. Attach the latch assembly using the four flange nuts previously removed. 3. Tighten the nuts to a torque of 3 Nm (26 in.-lb). 4. Connect P/J930 and P/J875. 5. Attach the latch rod to the slam latch and door latch assembly using the two hairpin clips previously removed. 6. Lock the solenoid by pressing on the round disk on the end of the solenoid shaft. 7. Attach the latch cover using the four screws previously removed. 8. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 9. Attach the three decorative covers to the front of the CAP door using the screws previously removed. 10. Tighten the screws to a torque of 1 Nm (8 in.-lb).

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11. Close the CAP door. 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

RH Mod Slam LatchOptional Door CAP


See Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349 and use the following procedures to remove and replace the CAP door RH Mod slam latch on the optional door CAPs.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the applicable CAP (see Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349). Note: A newer design of the CAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the CAP latch. To unlock the CAP, place a small screwdriver blade into the right hole and press against the solenoid shaft unlocks the CAP. If these holes are not present, perform the following steps to open the CAP. a. Remove the second magazine from the top from the CAP.

b. Locate the access hole adjacent to the CAP door latch. c. Insert a common-blade screwdriver through the hole, and locate the space between the solenoid and solenoid latch bar.

3. Apply pressure against the latch bar to unlock the solenoid. 4. Remove the four screws attaching the latch cover to the CAP door. 5. Remove the two hairpin clips attaching the latch rod to the slam latch and the door latch assembly. 6. Remove the two screws attaching the slam latch to the CAP door.

Replacement
1. Attach the RH Mod slam latch to the CAP door using the two screws previously removed. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Attach the latch rod to the slam latch and door latch assembly using the two hairpin clips previously removed. 4. Attach the latch cover using the four screws previously removed. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb).

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6. Close and open the CAP. If the CAP does not open easily, the slam latch might need to be adjusted. To do this, loosen the two 1/4-20 screws and reposition the slam latch downward. 7. Tighten the screws to a torque of 7 Nm (60 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

CAP Latch Solenoid AssemblyOptional Door


If your assembly resembles the ones in Figure 6-149 on page 6-348 and Figure 6-150 on page 6-349, use the following procedure and these figures to remove and replace the CAP latch solenoid assembly on the optional door CAPs. If you have the older model assembly, see CAP Door Latch AssemblyOptional Door on page 6-347, and replace the entire assembly.

Removal
1. Remove the four screws attaching the latch cover to the CAP door. 2. Disconnect P/J875. 3. Remove the two screws attaching the solenoid to the door latch assembly.

Replacement
1. Attach the solenoid assembly to the door latch assembly using the two screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect P/J875. 4. Attach the latch cover using the four screws previously removed. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Close the CAP door. 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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PCAP Latch AssemblyOptional Door


See Figure 6-151 on page 6-353 and use the following procedures to remove and replace the PCAP latch assembly on the optional door PCAP.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the PCAP (see Figure 6-143 on page 6-333). Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. To unlock the PCAP, place a small screwdriver blade into the left hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the PCAP. a. Insert a 3-in. common-blade screwdriver down through the access hole in the top of the PCAP latch cover.

b. Position the blade in the space between the end of the solenoid and the solenoid latch bar. c. Apply force against the latch bar to unlock the solenoid. Then open the PCAP using the latch handle.

3. Remove the four screws attaching the PCAP latch cover to the PCAP door. 4. Remove the four screws attaching the decorative cover to the PCAP door. 5. Remove three screws attaching the PCAP shelf to PCAP door. 6. Remove the shelf from the door. 7. Disconnect P/J875 and P/J930. 8. Remove the two hairpin clips attaching the latch rod to the PCAP latch assembly and the slam latch. 9. Remove the four flange nuts attaching the door latch assembly to the PCAP door. 10. Remove the door latch assembly from the front of PCAP door.

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Figure 6-151. PCAP Latch SystemOptional Door

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Replacement
1. Insert the cables with J930 and J875 and the door latch assembly into the opening in the PCAP door. 2. Attach the latch assembly using the four flange nuts previously removed. 3. Tighten the nuts to a torque of 3 Nm (26 in.-lb). 4. Route cables with J875 and J930 through the access hole in the side of the PCAP below the solenoid. 5. Connect P/J930 and P/J875. 6. Attach the latch rod to the slam latch and door latch assembly using the two hairpin clips previously removed. 7. Lock the solenoid by pressing on the round disk on the end of the solenoid shaft. 8. Attach the latch cover using the four screws previously removed. 9. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 10. Attach the PCAP shelf to the PCAP door using the three screws previously removed. Route the cartridge present cable (P727) through the slot in the shelf. 11. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 12. Attach the decorative cover to the PCAP door using the four screws previously removed. 13. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

LH Mod Slam LatchOptional Door PCAP


See Figure 6-151 on page 6-353 and use the following procedures to remove and replace the PCAP door LH Mod slam latch on the optional door PCAP.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the PCAP (see Figure 6-143 on page 6-333). Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. To unlock the PCAP, place a small screwdriver blade into the left hole and press against the solenoid shaft. If these holes are not present, perform the following steps to open the PCAP.

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a.

Insert a 3-in. common-blade screwdriver down through the access hole in the top of the PCAP latch cover.

b. Position the blade in the space between the end of the solenoid and the solenoid latch bar. c. Apply force against the latch bar to unlock the solenoid. Then open the PCAP using the latch handle.

3. Remove the four screws attaching the latch cover to the PCAP door. 4. Remove the two hairpin clips attaching the latch rod to the slam latch and PCAP latch assembly. 5. Open the PCAP, and remove the two screws attaching the slam latch assembly to the PCAP door.

Replacement
1. Attach the LH Mod slam latch to the PCAP door using the two screws previously removed. 2. Tighten the screws to a torque of 3 Nm (26 in.-lb). 3. Attach the latch rod to the slam latch and door latch assembly using the two hairpin clips previously removed. 4. Attach the latch cover using the four screws previously removed. 5. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 6. Close and open the PCAP. If the PCAP does not open easily, the slam latch may need to be adjusted. This is done by loosening the two 1/4-20 screws and repositioning the slam latch downward. 7. Tighten the screws to a torque of 7 Nm (60 in.-lb). 8. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

PCAP Latch Solenoid AssemblyOptional Door


If your assembly resembles the one in Figure 6-151 on page 6-353, use the following procedures and Figure 6-151 to remove and replace the door latch solenoid on the optional door PCAP. If you have the older model assembly, use the procedures in PCAP Latch Assembly Optional Door on page 6-352 and replace the whole assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Open the PCAP (see Figure 6-143 on page 6-333).

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Note: A newer design of the PCAP places two 5-mm (0.18-in.) diameter holes in the finger recess on the front of the PCAP latch. To unlock the PCAP, place a small screwdriver blade into the left hole and press against the solenoid shaft unlocks the PCAP. If these holes are not present, perform the following steps to open the PCAP. a. Insert a 3-in. common-blade screwdriver down through the access hole in the top of the PCAP latch cover.

b. Position the blade in the space between the end of the solenoid and the solenoid latch bar. c. Apply force against the latch bar to unlock the solenoid. Then open the PCAP using the latch handle.

3. Remove the four screws attaching the latch cover to the PCAP door. 4. Remove the four screws attaching the decorative cover to the PCAP door. 5. Remove the three screws attaching the PCAP shelf to the PCAP door. 6. Remove the shelf. 7. Disconnect P/J875. 8. Remove the two screws attaching the solenoid to the door latch assembly.

Replacement
1. Attach the solenoid assembly to the door latch assembly using the two screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Connect P/J875. 4. Attach the PCAP shelf to the PCAP door using the three screws previously removed. 5. Route J875 through the slot in the shelf. 6. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 7. Attach the decorative cover to the PCAP door using the four screws previously removed. 8. Tighten the screws to torque of 1.4 Nm (12 in.-lb). 9. Attach the latch cover using the four screws previously removed. 10. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 11. Close the CAP door. 12. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Ionization Smoke DetectorRoof


Removal
Follow the removal procedure in Photo-electric Smoke DetectorRoof (below) to remove an ionization detector.

Replacement
Ionization detectors are no longer in use. If you are replacing an old ionization detector, replace it with a photo-electric detector.

Photo-electric Smoke DetectorRoof


Use the following procedures to remove and replace the roof photo-electric smoke detector.

Removal
1. See LSM Entry Procedure on page xliv. 2. Loosen the set screw in the detector. 3. Twist the detector counterclockwise until the slots line up, then pull the detector downward.

Replacement
1. Twist the detector clockwise into the base assembly until it locks into place. 2. Tighten the set screw. 3. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Smoke Detector Base AssemblyRoof


Use the following procedures to remove and replace the roof smoke detector base assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove two Torx screws attaching the assembly to the roof. Discard these screws. 3. Disconnect J856 from P856, and J857 from P857.

Replacement
1. Connect J856 to P856, and J857 to P857. 2. Attach the assembly to the roof with the two Torx screws supplied in the new FRU kit. 3. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 PTP Motor/Encoder Assembly


See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the 4420/L5520 pass-thru motor/encoder assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Remove the three screws attaching the belt cover to the housing and motor shaft. 5. Disconnect the motor/encoder cable connectors P842 (motor) and P845 (tach) from the NC card connectors J842 and J845. 6. Loosen the screw in the split hub clamp on the motor pulley assembly. 7. Slide the pulley/hub clamp off the motor shaft leaving the belt over the pulley. Do not roll the belt on or off. 8. Remove the two screws attaching the motor to the motor support. 9. Remove the motor.

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Figure 6-152. 4420/L5520 Pass-thru Port FRU Components (Sheet 1 of 2)

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Figure 6-153. 4420/L5520 Pass-thru Port FRU Components (Sheet 2 of 2)

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Replacement
1. Attach the motor to the back side of the motor support using the two screws removed during motor removal. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 3. Position the belt around the motor pulley, and slide the pulley/hub clamp onto the motor shaft. 4. Rotate the pulley attached to the pass-thru leadscrew to center the motor pulley. 5. Tighten the screw in the motor pulley hub clamp without moving the pulley on the shaft. 6. Connect motor cable connector P842 to NC card connector J842. 7. Connect encoder cable connector P845 to the NC card connector J845. 8. Install the belt cover using the three 10-32 screws previously removed. 9. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 10. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 11. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 12. Tighten the four screws in the two previous steps to a torque of 3 Nm (26 in.-lb). 13. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 PTP Timing Belt


See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the timing belt.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Remove the belt cover by removing the three screws from the pass-thru housing and motor support. 5. Keep the hardware for installing the cover.

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6. Loosen the screw in the split hub clamp and slide the pulley off the leadscrew shaft. 7. Remove the defective timing belt.

Replacement
1. Ensure the spacer is on the leadscrew shaft. It might have come off when the pulley was removed. 2. Attach the replacement timing belt over the PTP motor pulley and around the leadscrew pulley. 3. Slide the pulley and split hub clamp with the timing belt around the pulley onto the leadscrew shaft. 4. Rotate the PTP motor pulley to center the belt and pulley on the leadscrew shaft. 5. Tighten the screw in the split hub clamp to secure the pulley to the shaft. 6. Attach the belt cover to the pass-thru housing and motor support using the three screws previously removed. 7. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 8. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 9. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 Master PTP Cam-Optical Sensor Cable Assembly


See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the optical sensor cable assembly attached to the master pass-thru cam.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Remove the belt cover from the pass-thru housing and motor support by removing the three 10-32 screws.

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5. Rotate the leadscrew pulley to position the pass-thru array to the slave side. 6. Disconnect the slave optical sensor cable connector J1 from the PTP sensors cable connector P1. 7. Remove the two cable clamps attaching the master optical sensor cable and the PTP sensors cable to the master pass-thru cam. 8. Remove the master side pass-thru cam by removing the 1/4-20 Torx screw from the top of the cam. 9. Remove the two 4-40 Torx screws from the bottom of the cam that secure the optical sensor cable assembly to the cam. 10. Disconnect the master optical sensor cable connector J1 from the PTP sensors cable connector P1. 11. Remove the defective optical sensor cable assembly.

Replacement
1. Connect the replacement optical sensor cable connector J1 to the PTP sensors cable connector P1. 2. Attach the optical sensor cable assembly to the bottom of the cam using the two 4-40 Torx screws previously removed. 3. Tighten the two screws to a torque of 0.6 Nm (5 in.-lb). 4. Attach the master side pass-thru cam to the pass-thru housing using the 1/4-in. screw previously removed. Do not tighten securely. 5. Attach the master PTP calibration assembly to the cam. 6. Hold a straight-edge against the two array targets above the master PTP calibration assembly. 7. Move the master cam in or out until it is coincident with the three targets (two directly above and the one on the calibration assembly). Keep the cam butted against the housing on the left side. 8. Tighten the screw attaching the cam to a torque of 5 to 7 Nm (45 to 60 in.-lb). 9. Remove the master PTP calibration assembly from the cam. 10. Attach the two cable clamps securing the master optical sensor cable and the PTP sensors cable to the master pass-thru cam using the two 4-40 Torx screws previously removed. 11. Attach the belt cover to the pass-thru housing and motor support using the three screws previously removed. 12. Tighten the three screws to a torque of 3 Nm (26 in.-lb).

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13. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 14. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 15. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 16. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 Slave PTP Cam-Optical Sensor Cable Assembly


See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the optical sensor cable assembly attached to the slave pass-thru cam.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the slave PTP calibration assembly to the slave pass-thru cam. 3. Remove the two 10-32 screws attaching the slave PTP light shield to the slave pass-thru cam. 4. Remove the two cable clamps attaching the optical sensor cable to the top of the slave pass-thru cam. 5. Remove the slave pass-thru cam by removing the 1/4-20 Torx screw that attaches the cam to the cam adjusting block. 6. Remove the two 4-40 Torx screws from the bottom of the cam that secure the optical sensor cable assembly to the cam. 7. Disconnect the optical sensor cable connector J1 from the PTP sensors cable connector P1. 8. Remove the defective optical sensor cable assembly.

Replacement
1. Connect the replacement optical sensor cable connector J1 to the PTP sensors cable connector P1. 2. Attach the optical sensor cable assembly to the bottom of the cam using the two 4-40 Torx screws previously removed. 3. Tighten the two screws to a torque of 0.6 Nm (5 in.-lb). 4. Attach the slave side pass-thru cam to the cam adjustment block with the 1/4 in. screw previously removed. Do not tighten securely.

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5. Attach the slave calibration assembly to the slave cam, and tighten the screw. 6. Using a straight-edge and the array targets above, move the slave cam in or out until the calibration target is coplanar with the other targets. 7. Keep the cam butted against the cam adjustment block on the right-hand side. 8. Tighten the screw attaching the slave cam to a torque of 5 to 7 Nm (45 to 60 in.-lb). 9. Remove the slave calibration assembly. 10. Attach the two cable clamps securing the slave optical sensor cable to the slave pass-thru cam using the two 4-40 Torx screws previously removed. 11. Attach the slave PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 12. Attach the slave PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 13. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 PTP Leadscrew Flange Bearings


There are two leadscrew flange bearings; one located on each end of the leadscrew. See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the leadscrew flange bearings.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Disconnect cable connectors P840 and P841 from the NC card. 5. Disconnect the PTP sensors cable connector P1-S from the slave optical sensor cable connector. 6. Remove the three 1/4-20 machine screws that attach the pass-thru housing to the pass-thru support bracket. 7. Remove the three screws attaching the belt cover to the pass-thru housing and motor support.

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8. Rotate the leadscrew pulley to position the array to the pulley end of the leadscrew. 9. Loosen the screw in the split hub clamp that secures the pulley to the leadscrew. 10. Slide the pulley/split hub clamp off the leadscrew with the belt on the pulley. 11. Slide the spacer off the leadscrew. 12. Remove the three 6-32 Torx screws that secure the bearing housing to the pass-thru housing on the slave end of the pass-thru housing. 13. Remove the three 10-32 Torx screws that secure the leadscrew nut to the leadscrew nut support. 14. Withdraw the nut and leadscrew until they are clear of the nut support, and then remove them from the housing in the other direction. 15. Remove the flange bearings from the leadscrew. The bearings might remain on the leadscrew, drop off the leadscrew, or remain in the housing as the leadscrew is removed. 16. Remove the wave spring washer from the slave end of the leadscrew.

Replacement
CAUTION: Corrosion damage: Do not handle the nut and leadscrew assembly with bare hands. Before handling the leadscrew, put on a pair of disposable plastic gloves. 1. Ensure that the wave spring washer is on the slave end of the leadscrew before installing the flange bearings. 2. Rotate the leadscrew nut to the master end of the leadscrew. 3. Guide the leadscrew into the pass-thru housing and nut support. 4. Insert one of the flange bearings into the pass-thru housing. 5. Place the end of the leadscrew into the flange bearing. This might require a slight rotation of the leadscrew. 6. Place the other flange bearing onto the leadscrew (outside the wave spring washer) and into the bearing housing. 7. Attach the bearing housing to the pass-thru housing with the three 6-32 screws previously removed. 8. Tighten the three screws to a torque of 1.4 Nm (12 in.-lb).

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9. Attach the leadscrew nut to the nut support using the three 10-32 screws previously removed. 10. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 11. Place the belt over the leadscrew pulley with the split hub clamp attached to the pulley. 12. Place the spacer onto the leadscrew. 13. Slide the pulley onto the leadscrew. 14. Rotate the motor pulley to center the belt and leadscrew pulley. 15. Tighten the screw in the split hub clamp to secure the pulley to the leadscrew. 16. Rotate the leadscrew pulley and check for smooth operation of the pass-thru port mechanism assembly from one limit to the other. 17. Mount the pass-thru housing to the pass-thru support bracket using the three 1/4-20 machine screws previously removed. 18. Level the pass-thru housing by placing the bubble portion of the combination square on the top surface of the master PTP cam. 19. Tighten the three screws while maintaining a level condition. 20. Slide a steel rule across the master and slave cams to check for equal height. If not, loosen the three screws and adjust the mechanism again until both conditions are met (level and equal height). 21. Tighten the three screws attaching the mechanism to a torque of 5 to 7 Nm (45 to 60 in.-lb). 22. Attach the belt cover to the pass-thru housing and motor support using the three 10-32 screws previously removed. 23. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 24. Connect cable connectors P840 and P841 to the NC card. 25. Connect the PTP sensors cable connector P1-S to the slave optical sensor cable connector. 26. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 27. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 28. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 29. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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4420/L5520 PTP Array Flange Bearings


There are two array flange bearings; one located on each end of the array shaft. See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the array flange bearings.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Remove the three 10-32 Torx screws attaching belt cover to the pass-thru housing and motor support. 5. Rotate the leadscrew pulley until the array is positioned at the pulley end of the leadscrew. 6. Remove the four 6-32 screws securing the array to the array support. 7. Remove the two extension springs from the nut support and array housing bushing. 8. Remove the four 10-32 Torx machine screws that attach the array housing bushing to the slide. 9. Remove the 1/4-20 nut attaching the array shaft to the array support. 10. Remove the array shaft, torsion spring, and two flange bearings.

Replacement
1. Insert one of the flange bearings onto the threaded end of the array shaft. 2. Attach the array housing bushing and array support to the array shaft using the 1/4-20 nut previously removed. 3. Tighten the nut to a torque of 5 to 7 Nm (45 to 60 in.-lb). 4. Attach the array shaft with the torsion spring and flange bearing in place to the slide. The top of the spring must engage with the slot in the array housing bushing. 5. Attach the array housing bushing to the slide using the four 10-32 Torx machine screws previously removed. 6. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 7. Attach the two extension springs to the nut support and array housing bushing posts.

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8. Attach the array to the array support using the four 6-32 screws previously removed. 9. Tighten the four screws to a torque of 1.4 Nm (12 in.-lb). 10. Rotate the leadscrew pulley and check for smooth operation of the array mechanism. 11. Attach the cover to the pass-thru housing and motor support using the three 10-32 screws previously removed. 12. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 13. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 14. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 15. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 16. Restore LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 PTP Extension Springs


See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the extension springs.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Remove the three 10-32 screws attaching the belt cover to the pass-thru housing and motor support. 5. Rotate the leadscrew pulley to position the array between the master and slave pass-thru cams. 6. Remove the springs by unhooking the ends from the posts located on the array housing bushing and the nut support.

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Replacement
1. Attach the ends of the two extension springs to the groove in the top of the posts located on the nut support and the array housing bushing. 2. Attach the belt cover to the pass-thru housing and motor support using the three 10-32 screws previously removed. 3. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 4. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 5. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 6. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 PTPNC Card


See Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the NC card. CAUTION: Component damage: Use the ESD grounding strap and observe the ESD procedures to prevent damage to the NC card components during the following removal and replacement procedures.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Disconnect cable connectors J840, J841, J842, J843, J844, and J845 from the NC card connectors. 5. Remove the four 6-32 Torx screws that attach the NC card to the PC mount support bracket.

Replacement
1. Attach the NC card to the PC mount support bracket using the four 6-32 Torx screws previously removed. 2. Tighten the screws to a torque of 1.4 Nm (12 in.-lb).

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3. Connect cable connectors J840, J841, J842, J843, J844, and J845 to the respective NC card connectors. 4. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 5. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 6. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 7. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

4420/L5520 PTP Slide


Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 and use the following procedures to remove and replace the slide on the pass-thru mechanism assembly.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Remove the three 10-32 Torx screws attaching belt cover to the pass-thru housing and motor support. 5. Rotate the leadscrew pulley until the array is positioned at the pulley end of the leadscrew. 6. Remove the four 6-32 screws securing the array to the array support. 7. Remove the two extension springs from the nut support and array housing bushing. 8. Remove the four 10-32 Torx machine screws attaching the array housing bushing to the slide. 9. Lift the array shaft up to remove from the slide. 10. Remove the 10-32 socket-head cap screw attaching the slide to the nut support. 11. Remove the slide.

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Replacement
1. Attach the slide to the nut support using the 10-32 socket-head cap screw previously removed. 2. Attach the array shaft with the torsion spring and flange bearing in place to the slide. The top of the spring must be engaged with the slot in the array housing bushing. 3. Attach the array housing bushing to the slide using the four 10-32 Torx machine screws previously removed. 4. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 5. Attach the two extension springs to the nut support and array housing bushing posts. 6. Attach the array to the array support using the four 6-32 screws previously removed. 7. Tighten the four screws to a torque of 1.4 Nm (12 in.-lb). 8. Rotate the leadscrew pulley and check for smooth operation of the array mechanism. 9. Attach the cover to the pass-thru housing and motor support using the three 10-32 screws previously removed. 10. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 11. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 12. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 13. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 14. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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4420/L5520 PTPBall Bushing/Shaft Kit


Use the following procedures and Figure 6-152 on page 6-359 and Figure 6-153 on page 6-360 to remove and replace the linear bearing on the support shaft of pass-thru mechanism assembly. CAUTION: Corrosion damage: Do not handle the support shaft and prelubricated linear bearing with bare hands. Before handling the support shaft and linear bearing, put on a pair of disposable plastic gloves.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove the two 10-32 screws attaching the master PTP calibration assembly to the pass-thru cam. 3. Remove the two 10-32 screws attaching the master PTP light shield to the pass-thru cam. 4. Disconnect cable connectors P840 and P841 from the NC card. 5. Disconnect the PTP sensors cable connector P1-S from the slave optical sensor cable connector. 6. Remove the three 1/4-20 Torx screws attaching the pass-thru housing to the pass-thru support bracket. 7. Remove the three 10-32 Torx screws attaching the belt cover to the passthru housing and motor support. 8. Rotate the leadscrew pulley until the array is positioned at the pulley end of the leadscrew. 9. Remove the four 6-32 screws securing the array to the array support. 10. Remove the two extension springs from the nut support and array housing bushing. 11. Remove the 10-32 socket-head cap screw attaching the slide to the nut support. 12. Remove the slide from the nut support. 13. Disconnect the motor/encoder cable connectors P842 (motor) and P845 (tach) from the NC card connectors J842 and J845. 14. Loosen the screw in the split hub clamp on the motor pulley assembly. 15. Slide the pulley/hub clamp off the motor shaft leaving the belt over the pulley. Do not roll the belt on or off. 16. Remove the two screws attaching the motor to the motor support.

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17. Remove the motor. 18. Remove the 6-32 set screw in the top of the nut support that secures the linear bearing inside the nut support. 19. Remove the four 6-32 Torx screws that attach the support shaft and rail support to the pass-thru housing. 20. Withdraw the support shaft toward the slave end of the pass-thru housing until it is clear of the nut support. The linear bearing should come out of the nut support with the shaft. 21. Lift the support shaft and linear bearing out of the housing. 22. Remove the linear bearing from the support shaft.

Replacement
Note: When installing the linear bearing onto the support shaft, the set screw hole in the linear bearing must be on top when the support shaft is oriented in the mounting position. 1. Insert the support shaft into the linear bearing. Carefully align the shaft with the bearing to prevent any binding that will force the ball bearings out of the linear bearing. 2. Rotate the linear bearing until the holes in the side of the support shaft align with the open area of the linear bearing. 3. Position the support shaft inside the pass-thru housing and nut support. 4. Attach the support shaft and rail support to the pass-thru housing using the four 6-32 Torx screws previously removed. 5. Slide the linear bearing into the nut support. 6. Align the set screw holes in the nut support and linear bearing. 7. Thread and tighten the set screw. 8. Tighten the four screws attaching the support shaft/rail support to the pass-thru housing to a torque of 1.4 Nm (12 in.-lb). 9. Attach the motor to the back side of the motor support using the two screws removed during motor removal. 10. Tighten the two screws to a torque of 1.4 Nm (12 in.-lb). 11. Position the belt around the motor pulley and slide the pulley/hub clamp onto the motor shaft. 12. Rotate the pulley attached to the pass-thru leadscrew to center the belt and motor pulley.

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13. Tighten the screw in the motor pulley hub clamp without moving the pulley on the shaft. 14. Connect motor cable connector P842 to NC card connector J842. 15. Connect encoder cable connector P845 to NC card connector J845. 16. Attach the slide to the nut support using the 10-32 socket-head cap screw previously removed. 17. Attach the two extension springs to the nut support and array housing bushing posts. 18. Attach the array to the array support using the four 6-32 screws previously removed. 19. Tighten the four screws to a torque of 1.4 Nm (12 in.-lb). 20. Mount the pass-thru housing to the pass-thru support bracket using the three Torx screws previously removed. 21. Level the pass-thru housing by placing the bubble portion of the combination square on the top surface of the pass-thru cam. 22. Tighten the three screws while maintaining a level condition. 23. Slide a steel rule across the master and slave cams to check for equal height. If not, loosen the three screws and adjust the mechanism again until both conditions are met (level and equal height). 24. Tighten the three screws attaching the mechanism to a torque of 5 to 7 Nm (45 to 60 in.-lb). Tighten the three screws while maintaining a level condition. 25. Tighten the three screws to a torque of 5 to 7 Nm (45 to 60 in.-lb). 26. Connect the slave optical sensor cable connector J1 to the PTP sensors cable connector P1. 27. Attach the cover to the pass-thru housing and motor support using the three 10-32 screws previously removed. 28. Tighten the three screws to a torque of 3 Nm (26 in.-lb). 29. Attach the master PTP light shield to the pass-thru cam using the two 10-32 screws previously removed. 30. Attach the master PTP calibration assembly to the pass-thru cam using the two 10-32 screws previously removed. 31. Tighten the four screws to a torque of 3 Nm (26 in.-lb). 32. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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4420/L5520 PTP Rotation Assembly


Figure 6-154 on page 6-378 and use the following procedures to remove and replace the PTP rotation assembly.

Removal
1. See LSM Entry Procedure on page xliv on the master LSM unit. 2. If the PTP array is at the master end of the PTP, proceed to Step 3. If it is not (if it is not accessible to you from within the master LSM unit), remove the belt cover (three screws) and rotate the lead until the PTP array is at the end of its travel in the master LSM. 3. Remove the four screws that secure the array support. 4. Lift off the array. 5. Remove the three screws that secure the array support to the rotation assembly. 6. Lift off the array support. 7. Disconnect P1-S from J1. 8. Disconnect P843 and P844 from J843 and J844, respectively, on the NC card. 9. Remove the screw that secures the cam to the PTP housing. 10. Remove the cam. 11. Remove the ends of the two springs around the posts in the rotation assembly. Be careful not to lose the springs. 12. Remove the four screws that secure the rotation assembly and lift out the assembly.

Replacement
1. Insert the new assembly into its housing. See Figure 6-154 on page 6-378 for the proper orientation. 2. Replace the four screws into the rotation assembly. 3. Tighten the screws to a torque of 1.4 Nm (12 in-lb). 4. Replace the ends of the two springs over the two posts coming up from the rotation assembly. 5. Re-seat the cam on the PTP housing. 6. Secure it with the screw you previously removed. 7. Tighten the screw to a torque of 3 Nm (26 in.-lb).

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8. Connect P843 and P844 to J843 and J844, respectively, on the NC card. 9. Connect P1-S to J1. 10. Replace the array on the array support. 11. Secure it with the four screws you removed. 12. Tighten the four screws to a torque of 1.4 Nm (12 in.-lb). 13. If necessary, replace the belt cover. Replace the three screws you removed. 14. Tighten the screws to a torque of 1.4 Nm (12 in.-lb). 15. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-154. 4420/L5520 PTP Rotation Assembly

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9320 CEM Master Receiver


The 9320 master receiver, containing the solenoid and release latch, is attached to the master CEM tower. In addition to your tool kit, you need the wall alignment tool and the tower adjustment tool (PN 3036616xx) to perform this procedure.

Removal
1. See LSM Entry Procedure on page xliv. 2. Power down the LSM that contains the master CEM. 3. Enter the LSM that contains the master side of the CEM. 4. Using Figure 6-155 as a reference, loosen the 3/8-in. nut that is attached to the cable restraint. 5. Disconnect the receiver connection to the PNC card at J845, and pull the cable and connector through the cable restraint. Figure 6-155. 9320 Master Solenoid Connector

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Figure 6-156. 9320 Master Tower Removal

6. Using Figure 6-156 as a reference, remove the three T-25 Torx screws from the tower base. 7. Remove the two T-15 Torx screws from the side of the drop ramp. 8. Remove the CEM tower from its base. 9. See Figure 6-157 on page 6-381, and remove the four Torx screws that attach the receiver to the tower.

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Figure 6-157. 9320 Master Receiver

Replacement
1. Attach the new receiver to the tower, using the four T-25 screws from Step 9 of the removal procedure. 2. Tighten the screws to a torque of 2.94 Nm (26 in.-lb). 3. Using the three T-25 screws from Step 6 of the removal procedure, loosely attach the tower to the base. 4. Using the two T-15 screws from Step 7 of the removal procedure, loosely attach the drop ramp. 5. See Figure 6-158 on page 6-382 (4410) or Figure 6-159 on page 6-383 (9310), and attach the wall alignment tool that matches your LSM type to the hand.

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Figure 6-158. 4410 Wall Alignment Tool

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Figure 6-159. 9310 Wall Alignment Tool

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6. Obtain the CEM tower alignment tool (PN 3036616xx). 7. Insert the tower tool between the plastic drop ramp and the cartridge path. Rest the tool on top of the tape path floor, near the far end of the drop ramp, as shown in Figure 6-160. Figure 6-160. 9320 Tower Tool Insertion

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Note: The following two steps interact with each other. CAUTION: The alignment of the receiver target with the wall alignment tool cannot differ more than 6.4 mm (0.25 in.) of the nominal mark on the tool. 8. Press the left side of the receiver ramp until it meets the tower tool. 9. Adjust the receiver ramp until the lower, vertical portion of the target meets the wall alignment tool, as shown in Figure 6-161 on page 6-386. 10. When you have completed the adjustments in Steps 8 and 9, tighten the three T-25 screws to a torque of 2.94 Nm (26 in.-lb) and the two T-15 screws to a torque of 1.36 Nm (12 in.-lb). 11. Recheck the receiver target adjustment for correct position. 12. Remove the tower tool. 13. Insert the solenoid connector and cable through the cable restraint. 14. Tighten the 3/8 in.-nut that holds the cable restraint. 15. Connect the solenoid cable to J845 on the PNC card. 16. Power on the LSM. 17. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-161. 9320 Target Alignment

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9320 CEM Slave Receiver


The 9320 slave receiver, containing the solenoid and release latch, is attached to the slave CEM tower. In addition to your tool kit, you need the wall alignment tool, a ruler, and the tower adjustment tool (PN 3036616xx) to perform this procedure.

Removal
1. See LSM Entry Procedure on page xliv. 2. Power down both LSMs that contain the CEM. 3. Enter the LSM that contains the master side of the CEM. 4. Using Figure 6-162 as a reference, loosen the 3/8-in. nut that is attached to the cable restraint. 5. Disconnect the receiver connection to the PNC card at J846 and push the cable and connector through the cable restraint. 6. Move to the slave side of the CEM. Figure 6-162. 9320 Slave Solenoid Connection

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7. Pull the solenoid cable and connector through the hole in the light shield. 8. Using Figure 6-163 as a reference, remove the three T-25 Torx screws from the tower base and the two T-15 Torx screws from the side of the drop ramp. 9. Remove the CEM tower from the CEM base. 10. Using Figure 6-164 on page 6-389 as a reference, remove the four Torx screws that attach the receiver to the tower. Figure 6-163. 9320 Slave Tower Removal

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Figure 6-164. 9320 Slave Receiver

Replacement
1. Attach the new receiver to the tower, using the four T-25 screws from Step 10 of the removal procedure. 2. Tighten the screws to a torque of 2.94 Nm (26 in.-lb). 3. Using the three T-25 screws from Step 8 of the removal procedure, loosely attach the tower to the base. 4. Using the two T-15 screws from Step 8 of the removal procedure, loosely attach the drop ramp. 5. See Figure 6-158 on page 6-382 (4410) or Figure 6-159 on page 6-383 (9310), and attach the wall alignment tool that matches your LSM type. 6. Insert the tower tool between the plastic drop ramp and the cartridge path. Rest the tool on top of the tape path floor, near the far end of the drop ramp, as shown in Figure 6-165 on page 6-391.

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Note: The following two steps interact with each other. CAUTION: The alignment of the receiver target with the wall alignment tool cannot differ more than 6.4 mm (0.25 in.) of the nominal mark on the tool. 7. See Figure 6-165 on page 6-391, and press the left side of the receiver ramp until it meets the tower tool. 8. See Figure 6-165 on page 6-391, and adjust the receiver ramp until the lower, vertical portion of the target meets the wall alignment tool. 9. When you complete the adjustments in Steps 7 and 8, tighten the three T-25 screws to a torque of 2.94 Nm (26 in.-lb) and the two T-15 screws to a torque of 1.36 Nm (12 in.-lb). 10. Remove the tower tool.

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Figure 6-165. 9320 Slave Receiver Alignment

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CAUTION: Critical measurement: The following step is the most critical one for correct operation of the CEM. If the measurement below is out of range, adjust the level position of the CEM (as described in the following step) to correct this distance. 11. See Figure 6-166. Using a ruler, measure the vertical distance between the top of the slave receiver target and the bottom of the array target immediately above it. This distance must be between 10.4 mm and 25.6 mm (0.41 in. and 1.01 in.). If an adjustment is required, perform the following steps. Figure 6-166. 9320 Slave Receiver Target Alignment

If the above measurement is less than the minimum range, the receiver cell is too high. To correct this: a. Loosen the leveling screw and bolt on the slave side, by equal amounts, until the measurement comes within the range specified above.

b. If the leveling screw and bolt come off the floor and the measurement is still not within range, continue loosening the slave side leveling screw and bolt until they are completely clear of the LSM floor. c. Move to the master side of the CEM and tighten the master side leveling screws, by equal amounts, until the measurement comes within the range specified previously.

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Note: The preceding adjustment results in an out-of-level condition that is acceptable. If the above measurement is greater than the maximum range, the receiver cell is too low. To correct this: a. Go to the master side of the CEM, and loosen the leveling screws until they are completely clear of the LSM floor.

b. Tighten the slave side screws until the measurement comes within range. Note: The preceding adjustment results in an out-of-level condition that is acceptable. 12. Re-check the receiver target adjustment for correct position. 13. As shown in Figure 6-167 on page 6-393, insert the solenoid connector and cable through the hole in the slave side CEM light shield. 14. Move to the master side of the CEM. Figure 6-167. 9320 Slave Solenoid Cable

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15. Connect the solenoid cable to J846 on the PNC card. 16. Tighten the 3/8-in. nut that holds the cable restraint. 17. Power on the LSMs. 18. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

9320 CEM Assembly


You must first remove both the master and slave towers before attempting to replace the 9320 CEM base assembly. In addition to your tool kit, you need the wall alignment tool, a level, a ruler, and the tower adjustment tool (PN 3036616xx) to perform this procedure.

Removal
1. See LSM Entry Procedure on page xliv. 2. Power down both LSMs that contain the CEM. 3. Enter the LSM that contains the master side of the CEM. 4. Using Figure 6-168 on page 6-395 as a reference, perform the following: a. Disconnect the master receiver connection to the PNC card at J845.

b. Disconnect the slave receiver connection to the PNC card at J846. c. Disconnect the PTP/CEM power cable connection to the PNC card at P841.

d. Disconnect the PTP/CEM signal cable connection to the PNC card at P840. 5. Loosen the 3/8-in. nut that is attached to the cable restraint. 6. Remove both solenoid cables by pulling them through the restraint. Push the slave solenoid cable through to the slave side.

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Figure 6-168. 9320 CEM Cable Removal

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Figure 6-169. 9320 Cable Restraint

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7. Using Figure 6-170 as a reference, remove the three T-25 Torx screws from the tower base and the two T-15 Torx screws from the side of the drop ramp. 8. Remove the master CEM tower from the CEM base. 9. Move to the slave side of the CEM. 10. Pull the slave receiver solenoid cable and connector through the hole in the light shield. 11. Remove the three T-25 Torx screws from the tower base. 12. Remove the two T-15 Torx screws from the side of the drop ramp. 13. Remove the CEM tower from the CEM base. Figure 6-170. 9320 Master Tower Removal

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14. Using Figure 6-171 as a reference, raise the adjustment screw and bolt. Figure 6-171. 9320 Slave Tower Adjustment Screw and Bolt

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15. Using Figure 6-172 as a reference, remove the two 3/8-in. nuts that attach the light shield to the LSM wall. Remove the light shield. 16. Move to the master side of the CEM. Figure 6-172. 9320 Light Shield

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17. Using Figure 6-173 as a reference, raise the two leveling adjustment screws in the CEM base. 18. Using a 7/16-in. wrench, remove the two KEPS nuts that attach the CEM to the LSM floor. 19. Tilt the CEM assembly up and carefully remove the assembly from the wall opening and the LSM. Figure 6-173. 9320 KEPS Nut Removal

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Replacement
1. Insert the CEM assembly between the LSMs. Align the holes in the base of the master CEM with the four studs on the bottom of the PTP wall. Thread two KEPS nuts (PN 1028058) only on the floor studs shown in Figure 6-174. Using a 7/16-in. socket wrench, tighten the nuts from 5.08 to 6.77 Nm (45 to 60 in.lb). 2. Verify that the two adjustment screws are at least 7 mm (0.25 in.) off the LSM floor. Figure 6-174. 9320 CEM Base Assembly

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3. Move to the slave side of the CEM. 4. Remove the level from the combination square. Place the level on the bottom plate as shown in Figure 6-175. If the bottom plate requires upward adjustment, lower the screw and bolt until they meet the LSM floor. Then tighten them equal amounts to achieve a level condition. Figure 6-175. 9320 Slave CEMPrimary Leveling

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CAUTION: Critical adjustment: If the slave portion must move down, you must adjust the master portion up by using the two leveling screws on the master side. Do this by lowering the screws to the floor, then tightening them equal amounts. Note: At this leveling step, you must adjust either the master or slave side leveling screws. 5. Move to the master side of the pass-thru port. 6. Using Figure 6-176 on page 6-404 as a reference, use the level from the combination square. Place the level on the bottom plate. If the motor side of the plate needs to be raised, turn the adjustment screw nearest the motor. If the motor side of the plate needs to be lowered, do not adjust. This condition cannot be corrected.

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Figure 6-176. 9320 Master CEMLeveling

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7. Move to the slave side of the CEM. 8. Place the level on the CEM plate (as shown in Figure 6-177). Use the adjustment screw and bolt, as required, to achieve a level condition. 9. When leveling is complete, be sure that the bolt and all adjustment screws securely meet the LSM floor. Figure 6-177. 9320 Slave CEMSecondary Leveling

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Figure 6-178. 9320 Slave Light Shield Attachment

10. Using Figure 6-178 as a reference, obtain the light shield (PN 3131486xx). 11. Remove the two 3/8-in. nuts shown above. 12. Insert the light shield on the studs and thread, but do not tighten, the two nuts. 13. Obtain the tower tool. Lay the tool horizontally as shown. 14. Lower the light shield until it touches the tool. 15. Tighten the two 3/8-in. nuts. 16. Remove the tower tool. 17. Recheck the level conditions for both master and slave sides. Adjust as required. 18. Lower any leveling screws or the bolt (if any are still off the floor) until they meet the LSM floor. Tighten the screws or bolt an additional 1/4 turn. Note: There are cases where completely level conditions cannot be obtained. Level as well as possible.

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19. Obtain the master tower receiver (PN 3131476xx) and its five mounting screws. 20. Move to the master side of the CEM. 21. Loosely attach the master tower to the CEM base plate using the three T-25 and two T-15 screws. 22. Use Figure 6-179 as a reference. Obtain the cable restraint (PN 10075150) and 3/8in. nut. Loosely attach the restraint to the upper right stud. Figure 6-179. 9320 Cable Restraint and PNC Card

23. Insert the master solenoid connector through the restraint and plug the connector into J845 on the PNC card. 24. Obtain the wall alignment tool for your LSM (4410 or 9310), and either: For a 4410 LSM, attach the PTP Put cell/tape transport extension. For a 9310 LSM, set the tool to the lengthened (CEM Put cell/tape transport) position.

25. Position the wall alignment tool at the receiver (CEM) target.

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CAUTION: Critical adjustment: Use of the tower tool is essential for proper operation of the CEM. Intermittent failures of the mechanism will result if the tool is not used to set the gap between the path and the tower assembly. 26. Obtain the tower tool (PN 3036616xx). Insert the tool between the plastic drop ramp and the CEM cartridge path. Rest the tool on top of the tape path floor, near the far end of the drop ramp, as shown in Figure 6-180. Figure 6-180. 9320 Tower Tool Insertion

Note: The following two steps interact with each other. 27. Press the left side of the receiver ramp until it meets the tower tool, as shown in Figure 6-181 on page 6-409. CAUTION: The alignment of the receiver target with the wall alignment tool cannot differ more than 6.4 mm (0.25 in.) of the nominal mark on the tool. 28. As shown in Figure 6-182 on page 6-410, adjust the receiver ramp until the lower, vertical portion of the target meets the wall alignment tool.

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Figure 6-181. 9320 Master Receiver Ramp Alignment

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Figure 6-182. 9320 Master Receiver Target Alignment

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29. When the adjustments in Steps 27 and 28 are complete, tighten the three T-25 screws to a torque of 2.94 Nm (26 in.-lb) and the two T-15 screws to a torque of 1.36 Nm (12 in.-lb). 30. Re-check the receiver target adjustment for correct position. 31. Remove the tower tool. Figure 6-183. 9320 Slave Tower Attachment

32. Obtain the slave receiver tower and attaching hardware. 33. Move to the slave side of the CEM. 34. See Figure 6-183 and, using a T-25 Torx driver, thread three screws (PN 10310468) into the holes in the base. Do not tighten at this time.

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CAUTION: Component damage: For the next step, be sure that the shorter T-15 screw is placed on the bottom and that the longer screw is placed on the top. 35. Using a T-15 Torx driver, thread the two screws into the side plate of the tower. Do not tighten. Note: The top screw must pass through the plastic bar. 36. Obtain the wall alignment tool and attach it to the turntable, and either: For a 4410 LSM, attach the PTP Put cell/tape transport extension. For a 9310 LSM, set the tool to the lengthened (PTP Put cell/tape transport) position.

37. Obtain the tower tool. Rest the tool on top of the tape path floor, near the far end of the drop ramp, as shown in Figure 6-184 on page 6-413. Note: The following two steps interact with each other. 38. Adjust the receiver ramp until the target meets the wall alignment tool, as shown in Figure 6-184 on page 6-413. 39. Press the left side of the receiver tower until it meets the tower tool. CAUTION: Critical alignment: The alignment of the receiver target with the wall alignment tool cannot differ more than 6.4 mm (0.25 in.) of the nominal mark on the tool.

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Figure 6-184. 9320 Slave Receiver Alignment

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40. When both alignments in Steps 36 and 37 are complete, tighten the three T-25 screws to a torque of 2.94 Nm (26 in.-lb) and the two T-15 screws to a torque of 1.36 Nm (12 in.-lb). 41. Re-check the receiver target with the wall alignment tool. 42. Remove the tower tool. CAUTION: Critical adjustment: The following step is the most critical one for correct operation of the CEM. If the measurement below is out of range, adjust the level position of the CEM (as described in the following step) to correct this distance. 43. See Figure 6-185. Using a ruler, measure the vertical distance between the top of the slave receiver target and the bottom of the array target immediately above it. This distance must be between 10.4 mm and 25.6 mm (0.41 in. and 1.01 in.). If adjustment is required, perform the following steps. Figure 6-185. 9320 Slave Receiver Target Alignment

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If the above measurement is less than the minimum range, the receiver cell is too high. To correct this: a. Loosen the leveling screw and bolt on the slave side, by equal amounts, until the measurement comes within the range specified previously.

b. If the leveling screw and bolt come off the floor and the measurement is still not within range, continue loosening the slave side leveling screw and bolt until they are completely clear of the LSM floor. c. Move to the master side of the CEM and tighten the master side leveling screws, by equal amounts, until the measurement comes within the range specified previously. Note: The preceding adjustment results in an out-of-level condition that is acceptable. If the above measurement is greater than the maximum range, the receiver cell is too low. To correct this: a. Go to the master side of the CEM and loosen the leveling screws until they are completely clear of the LSM floor.

b. Tighten the slave side screws until the measurement comes within range. Note: The preceding adjustment results in an out-of-level condition that is acceptable. 44. Verify that the side-to-side level condition is still adequate on both the master and slave sides of the CEM. Adjust as required. 45. Lower any leveling component (leveling bolt or screws) on both sides of the CEM that are not in contact with the floor. Adjust them until they touch the LSM floor, and tighten them an additional 1/4 turn. 46. Route the slave solenoid connector and cable through the grommet in the light shield, as shown in Figure 6-186 on page 6-416. 47. Move the robotic arm with the alignment tool to the slave CEM GET target. 48. Set the wall alignment tool to the outer array position (remove the CD extension for the 4410 LSM wall alignment tool).

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Figure 6-186. 9320 Slave Solenoid Cable Routing

CAUTION: Critical alignment: The distance to the slave Get target cannot differ more than 6.4 mm ( 0.25 in.) of the nominal mark on the tool. Adjust as required, following Steps 48 and 49. 49. As shown in Figure 6-187 on page 6-417 (4410 LSM) or in Figure 6-188 on page 6-418 (9310 LSM), measure the distance to the lower portion of the slave CEM Get target. 50. If adjustment is required, use a T-15 Torx driver, loosen the two Get target adjustment screws (shown in Figure 6-187 on page 6-417 or Figure 6-188 on page 6-418), and align the target to the wall adjustment tool. 51. Once the target is aligned, tighten the two screws on the side plate of the tower to a torque of 1.36 Nm (12 in.-lb). 52. Move to the master side of the cartridge exchange mechanism. 53. Guide the slave solenoid cable through the plastic cable restraint, and tighten the nut on the restraint.

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Figure 6-187. 9320 Slave Get Target Alignment (4410 LSM)

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Figure 6-188. 9320 Slave Get Target Alignment (9310 LSM)

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54. Using Figure 6-189 as a reference, attach the slave solenoid connector to J846 on the PNC card. Figure 6-189. 9320 PNC Card Solenoid Connections

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Final Checks
Be sure that: 1. The tower adjustment tool is removed from the CEM mechanism. 2. All other tools and hardware are removed from both LSMs. 3. Any wall alignment tools are removed from the robotic arms. 4. For 4411 LSMs, the cables to the LU (wrist) cables have been reconnected. 5. The power, signal, and solenoid cables to the PNC card are properly connected. CAUTION: Component damage: Be sure that you check the orientation of the signal cable for the following step. 6. See Figure 6-190 on page 6-421 and note the key slot on connector J840. To prevent damage, verify for proper orientation before connecting the PTP/CEM signal cable connector P840 to PNC card connector J840. 7. Connect PTP/CEM power cable connector P841 to PNC card connector J841. 8. Attach the cables to the bottom left-hand side of the PTP wall with a cable clamp (F/N 40) and the existing nut on the array cover. 9. Power on the LSMs. 10. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-190. 9320 PNC Card

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PNC Card
See Figure 6-190 on page 6-421 and use the following procedures to remove and replace the PNC card.

Removal
1. See LSM Entry Procedure on page xliv. 2. See Electrostatic Discharge (ESD) Damage Prevention on page lii. 3. Power down the master LSM. 4. Remove the following cables and connectors at the PNC card: a. P841 (PTP/CEM power)

b. P840 (PTP/CEM signal) c. P845 (master solenoid)

d. P846 (slave solenoid) e. P840 (PTP/CEM motor)

5. Using a T-15 Torx driver, remove the four screws that attach the PNC card to the CEM assembly.

Replacement
1. Using a T-15 Torx driver, thread in four screws and attach the PNC card to the CEM assembly. 2. Attach the following cables and connectors at the PNC card: a. P841 (PTP/CEM power)

CAUTION: Component damage: Be sure that you check the orientation of the signal cable for the following step. b. P840 (PTP/CEM signal) c. P845 (master solenoid)

d. P846 (slave solenoid) e. P840 (PTP/CEM motor)

3. Power on the LSMs. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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DDM Card
See Figure 6-191 on page 6-424 and use the following procedures to remove and replace the DDM card.

Removal
1. See LSM Entry Procedure on page xliv. 2. Power down the CD. 3. Remove the 12 screws and flat washers attaching the air box cover to the CD wall, and gently pull the air box cover out so the DDM card cables are accessible. 4. Disconnect P150-0 and P151A, P151B, P151C, and P151D (as applicable) from the DDM card. The M22 units do not use P151B or P151D. 5. Remove the nine mounting screws from the DDM card and remove the card.

Replacement
1. Attach the DDM card using the nine screws, making sure the displays are oriented through the cutouts in the air box cover. 2. Connect J/P 150-0 and 151A, 151B, 151C, and 151D (as applicable) to the DDM card (151A for Transport 0, 151B for Transport 1, 151C for Transport 2, 151D for Transport 3). Use tie wraps to pull back onto themselves the unused power connectors P150-1, P150-2, and P150-3. 3. Attach the air box cover to the CD wall with the 12 screws and flat washers. 4. Power on the CD. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures. Note: Perform the following steps to increase the panel intensity on units that have drive code Level 390 (4.2/C.2) or higher installed: 1) Ensure the transport is ready (loaded or unloaded). 2) Press the REWIND and the UNLOAD switches simultaneously (previous levels required pressing the REWIND switch).

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Figure 6-191. DDM Card

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DD Card
See Figure 6-192 on page 6-426 and use the following procedures to remove and replace the DD card.

Removal
1. See LSM Entry Procedure on page xliv. 2. Power down the CD. 3. Remove the 12 screws and flat washers attaching the air box cover to the CD wall, and gently pull the air box cover out so the DD card cables are accessible. 4. Disconnect P150-x and P151-x from the suspect DD card. 5. Remove the six mounting screws from the DD card and remove the card.

Replacement
1. Attach the DD card using the six screws, making sure the displays are oriented through the cutouts in the air box cover. 2. Connect J/P 150-x and 151-x. 3. Attach the air box cover to the CD wall with the 12 screws and flat washers. 4. Power on the CD. 5. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures. Note: Perform the following steps to increase the panel intensity on units that have drive code Level 390 (4.2/C.2) or higher installed. 1) Ensure the transport is ready (loaded or unloaded). 2) Press the REWIND and UNLOAD switches simultaneously (previous levels required pressing the REWIND switch).

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Figure 6-192. DD Card

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Operator Switch Panel (DO Card)


See Figure 6-193 on page 6-428 and use the following procedures to remove and replace an operator switch panel.

Removal
1. See LSM Entry Procedure on page xliv. 2. Power down the CD. 3. Remove the 12 screws and flat washers attaching the air box cover to the CD wall, and gently pull the air box cover out so the DO card and cables are accessible. 4. Disconnect J/P 145 from the DO card. 5. Remove the four mounting screws securing the card. 6. Remove the operator switch panel.

Replacement
1. Align the mounting holes on the operator switch panel. 2. Install the four mounting nuts and flat washers. 3. Connect J/P 145 on the operator switch panel. 4. Attach the air box cover to the CD wall with the 12 screws and flat washers. 5. Power on the CD. 6. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Figure 6-193. Operator Switch Panel (DO Card)

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WindowWall (9310/L5510 Only)


Use the following procedures to remove and replace the viewing window. CAUTION: LIfting hazard: Two people are required to replace the viewing window in a wall.

Removal
1. See LSM Entry Procedure on page xliv. 2. Remove cartridge arrays adjacent to the window. 3. With another person outside the LSM holding the window, enter the LSM and remove the 12 screws that secure the window to the wall. Put the screws in a safe place; you will need them later. 4. Remove the window and place it in a safe place.

Replacement
1. With another person outside the LSM holding the window, enter the LSM and replace the screws you removed in Step 3 of the removal procedure. 2. Tighten the screws to a torque of 4.5 Nm (40 in.-lb). 3. Replace the cartridge arrays you removed in Step 2 of the removal procedure. 4. Restore the LSM; see Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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Equipment Restoral Procedures

This chapter provides instructions for returning the automated cartridge system (ACS) to normal operation after a maintenance action has been performed.

Library Management Unit Restoral


Be sure that: All cards are installed and properly seated. All cables are installed and seated. All cable strain reliefs are secure. All jumpers installed during maintenance are removed.

In addition, perform the following tasks: 1. Visually check the library management unit (LMU) for loose parts, loose connectors, tools, and so on. 2. Inspect filters, and clean or replace, as required. 3. Apply power to the LMU. 4. Perform an IPL on the unit. 5. Perform diagnostic routines on the LMU. 6. Put all switches in normal modes. 7. Advise the customer that service action has been completed. 8. Be sure that customer programs operate correctly. 9. Refer to Universal FDR Code Guide (PN 95419) and complete the field data report (FDR). 10. Terminate the service call.

Library Control Unit Restoral


Be sure that: All cards are installed and properly seated. All cables are installed and seated. All cable strain reliefs are secure.

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Library Storage Module Restoral

All jumpers installed during maintenance are removed.

In addition, perform the following tasks: 1. Visually check the library control unit (LCU) for loose parts, loose connectors, tools, and so on. 2. Inspect filters, and clean or replace, as required. 3. Apply power to the LCU. 4. Perform diagnostic routines on the LCU. 5. Put all switches in normal modes. 6. Advise the customer that service action has been completed. 7. Be sure that customer programs operate correctly. 8. Refer to Universal FDR Code Guide (PN 95419) and complete the field data report (FDR). 9. Terminate the service call.

Library Storage Module Restoral


When access to the library storage module (LSM) has been obtained, it is imperative that all safety procedures be observed and the LSM be secured properly before powering-up the LCU. Follow the procedure below to ensure safe operation of the unit during restoral to customer operation. Be sure that: All cards are installed and properly seated. All cables are installed and secured away from moving components. All cable strain reliefs are secure. Any jumpers installed during maintenance are removed.

In addition, perform the following tasks: 1. Visually check the LSM for loose parts, loose connectors, tools, and so on. 2. Replace any cartridges that were removed during maintenance. 3. Close, align and secure the inner door assembly (if opened). 4. Position the theta arm: On the 4410, position the Z channel assembly in front of the access door (not in contact with the mechanical stop). On the 9310/L5510, position the theta arm so the home position mark (0) on the theta turns counter label is at the top.

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Library Storage Module Restoral

5. Check the emergency power-off (EPO) system for an operable condition by using the following procedure: a. Place the LCU power ON/OFF switch in the ON position.

b. Press the EPO button inside the LSM access door The LSM should perform an EPO. c. Turn the operator panel ON/OFF switch to the OFF position.

d. Reset the LSM with the EPO reset button inside the LCU on the AC power supply. e. f. g. Turn the AC Box CB2 on. Turn the operator panel ON/OFF switch to the ON position. Press the EPO switch on the LCU front panel. The LSM should perform an EPO. h. Repeat Steps 5c through 5f. 6. Ensure that all transports are ready (the green LED above the READY switch is on). 7. Close and lock the LSM access door. 8. IPL the LSM. CAUTION: Long initialization required: A long initialization process must be forced to occur if any one of the following field replaceable units (FRUs) have been removed and replaced: Camera Vision lamp Finger or any part of a hand assembly Wrist Z leadscrew Theta drive Theta crash stop

CAUTION: Long initialization required: A long initialization is also required if the physical configuration of the LSM is changed (that is, conversion from one wall to another) or the adjustment of any wall.

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Long Initialization Procedure

To force a long initialization process, see Long Initialization Procedure. 9. Perform applicable diagnostic routines on the LSM. 10. Put all switches in normal modes. 11. Install the side cover (if removed) and close the front panel on the LCU. 12. Advise the customer that service action has been completed. 13. Be sure that customer programs operate correctly. 14. Refer to Universal FDR Code Guide, (PN 95419) and complete the field data report (FDR). 15. Terminate the service call.

Long Initialization Procedure


The non-volatile read-access memory (NVRAM) in the LCU stores data for the camera, lamp, Z, and panel calibrations and Hands 0 and 1 adjust. If an LSM is powered off and then on, or re-IPLed, the NVRAM values are used during the initialization process. Some of the phases of initialization are internally bypassed and the needed data is loaded from the NVRAM instead of from the actual calibration of these devices. Some FRUs force the long initialization process which erases the CRC field of the NVRAM and loads new calibration data into the NVRAM. These FRUs include the LZ, LW, LO (0 and 1), LP (0 and 1) or LPP (0 and 1) cards, the REI and LCU motherboards, and LCU ID change. However, some FRUs, such as the hand, camera, lamps, wrist, and Z leadscrew do not automatically force a long initialization. Likewise, altering the wall alignment and configuration does not generate a long initialization. Therefore, when one of these components is altered or replaced, a long initialization is required. To force a long initialization from the 4430 LMU; 1. Enter the Utility environment. 2. Type IPL DE=x LONG (where x is the LSM number and LONG forces a long initialization); otherwise, a short initialization is performed.

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Principles of Operation

This chapter describes the functions completed by the library management unit (LMU), and the library storage module (LSM). The 4480 Cartridge Subsystem is also a major part of the automated cartridge subsystem (ACS), but only that portion that is directly related to the ACS is described in this manual. For further information on the 4480 Cartridge Drive Subsystem or other tape drive systems, refer to the maintenance manuals for those devices.

System Overview
An ACS consists of cartridges and attached cartridge transports that automatically mount and dismount cartridges. It is attached to single or multiple host systems through customer-supplied terminal control units. The ACS consists of five major components (see Figure A-1 on page A-2): A host software component (HSC) operating in each host computer One or two LMUs controlling multiple, connected LSMs LSMs storing and handling cartridges Library control units (LCUs) controlling cartridge activity Cartridge subsystems with cartridge drives (CDs) attached to the LSMs

From a system viewpoint, commands are issued from the host to the cartridge tape Control Units in the same manner as with other I/O storage devices. The difference comes in the handling of the mount/dismount procedures associated with the cartridges. Instead of issuing a message that is printed to an operator console display terminal, the command is sent to the LMU to mount a specific cartridge, located in a particular LSM, into a specified transport located in a CD that is attached to an LSM in the library.

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System Overview

Figure A-1. ACS Components

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Host Software Component

Host Software Component


The HSC serves as the interface between the host operating system that requests tape processing and the LMU that controls the physical cartridge mount/dismount operations performed by the LSMs. The major functional responsibilities of the HSC are software installation and initiation, job processing (transport allocation and cartridge mounting), operator commands, utility programs, log processing, and recovery processing. The HSC is the initiator of the library requests and therefore of most LMU and LSM actions.

Library Management Unit


The LMU is the interface between host computers and LSMs. The LMU supports up to 16 host interfaces (terminal control unit protocol), and controls up to 16 LSMs. Communication to the LSMs is through a redundant local area network (LAN). A second LMU can be added to create a Dual LMU (DLMU) configuration. The purpose of the DLMU is to protect the ACS from one failure within the LMUs and the LAN. DLMU is accomplished through code changes in the HSC, LMU, and LSM. Each LMU is connected to each host through two 3270 interfaces. One LMU is designated as a Master LMU and the second LMU is designated as a Standby LMU. A system of cross-polling and acknowledging verifies LMU integrity and determines when a switchover is necessary (the Standby becomes the Master and the Master becomes the Standby).

LMU Functional Components


The LMU is a microprocessor-based controller including the following functional parts (see Figure A-2 on page A-4): Central processor module (CPM) Memory Peripheral interface module (PIM) Interface processor modules (IPMs) Operator panel, service panel Field replaceable unit (FRU) identification.

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Library Management Unit

Figure A-2. LMU Block Diagram (IBM Hosts)

Central Processor Module (LA Card)


The central processor module (CPM) includes a microprocessor, miscellaneous control functions, PROM (used for power-on, initial hardware check, and initial boot code), the disk drive interface, and LMU bus interface. The CPM is located on the LA card at Location D1 in the card cage. Figure A-3 on page A-5 shows a block diagram of the LA card. The disk drive interfaces support one to four floppy disk drives; however, only two drives are included in the LMU. They are used for program and diagnostic code loading and for error, statistical, and performance logging. They use double-sided, double-density, 1.2 MB, 5-1/4-inch diskettes. The file format is compatible to MS-DOS.

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Figure A-3. CPM (LA Card) Block Diagram

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Library Management Unit

Memory (LI Card)


The memory board at Location B1 in the card cage consists of the PIMBUS interface, the memory paging unit, and 512 KB of static RAM (SRAM) used for full IPL, functional and diagnostic code and data. Figure A-4 on page A-7 is a block diagram of the LI card. The PIMBUS I/F passes addresses and data to and from the LI card when accessed by the Z8002 processor on the LA card. This I/F also checks parity going and coming; it does not generate parity since parity is stored in memory. Parity is checked at all addresses whether destined for the LI card or not, and on all data reads and writes of the LI or LB card. The memory paging unit (MPU) combines the address placed on the bus by the Z8002 processor (virtual address) and combines it with the contents of the page register to generate the physical address to the memory devices. The word-wide page register contains one byte as program page and one byte as data page. Within each byte the least significant 6 bits are written with the page number desired. The most significant 2 bits are written with the page size desired. Each space (program and data) can have different page size and number at a time. A memory block is 64 KB long, consisting of side-by-side 32K x 8 chips. Four blocks of data and four blocks of program memory make up the 8 x 64K or 512K total memory. Also, 64K x 1 SRAMs are the parity memory devices. The data transceivers act as the interface from the PIMBUS to the SRAM data bus. An AND, OR, INVERT (AOI) chip generates enable to the transceivers to prevent contention over the PIMBUS. Parity of the data on the PIMBUS is checked by two 9-bit parity generators. The output of the parity checking circuit enables Me PE if incorrect parity exists. The control buffers either buffer or invert the control signals from the PIMBUS. Address latches latch the address present on the PIMBUS with each address strobe high to allow time for the address decoders to function.

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Figure A-4. Memory (LI Card) Block Diagram

Peripheral Interface Module (LB Card)


The LB card at Location C1 is the peripheral interface module (PIM). It provides the external interfaces for attachment of peripherals. Figure A-5 on page A-8 is a block diagram of the LB card. The LB card generates a 16 MHz, two 8 MHz, and two 4 MHz clocks that are buffered and driven to the three row connector for distribution along the LMU motherboard. The LB supports programmable frequency margining. The local area network (LAN) interfaces are the paths through which the host transmits command information to the LCU. LAN 1 is identical to LAN 0 and is provided for redundancy. The two RS-232 interfaces provide asynchronous serial communications. Baud rates of 300, 600, 1200, 2400, 4800, and 9600 are software selectable. These interfaces are intended for attachment of a maintenance laptop computer, a local 392X Detached Diagnostic Device, or through a modem to Central Support Services. The interface connectors are female D-25 connectors wired as RS-232C DCE in conformance with the UUT/392X Interface Definition. A power supply interface provides for power supply margining and power-off sequencing. When the LB senses that the power-off switch is activated, it signals the processor of this condition. Now the processor has the option of allowing power-off to complete or postponing it to allow error logging to the floppy.

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Library Management Unit

Figure A-5. PIM (LB Card) Block Diagram

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Library Management Unit

The +5 V, +12 V, and -12 V are supplied from power supplies located on the LMU frame. The -9 V required by the LAN transceivers are supplied by two DC-to-DC convertors located on the LB card. A time-of-day clock is provided for statistics and error logging. The clock with a backup power, supplied by a long life 3.6 V tadiran battery, provides the correct time-of-day when power is restored to the LMU. Programmable timers are provided for watchdog timing and software clocking. A high-speed internal command/data bus (PIM Bus) interconnects the CPM, memory module, and the peripheral interface module. Operator and service panel interfaces provide for control access and data display at the LMU. The air temperatures at five different locations on the LMU are monitored by the LB card by the analog to digital convertor. The various power supply voltages on the LMU are also monitored by the analog to digital convertor.

Interface Processor Module(s) (LC Card)


The Interface Processor Modules (IPMs) are microprocessor-controlled interfaces to allow attachment to a terminal control unit communications controller. There are from one to 16 IPMs (LC cards, Locations E1 through V1) in each LMU. They provide the means for communication with IBM-compatible host processors. The IPM emulates an IBM 3278 terminal and conforms to the electrical protocols required. An IPM provides a single 3278 interface to the terminal control unit. It includes a high-speed 8x305 microprocessor, local RAM for 3278 screen emulation and data transfer buffering to/from the LMU, and local PROM for IPM firmware. The LMU Bus connects the CPM to the IPMs. Figure A-6 on page A-11 is a block diagram of the LC card. The IPM is an 8x305 microcontroller-based system which uses the 8x310 interrupt coprocessor. An interrupt capability is required because of the high priority and time criticality of the 3270 interface. Masking and prioritization of interrupts are handled by the 8x310. All I/O of the micro controller is handled over a single internal address/data bus, the 8x305 interface vector (IV) Bus. Assorted I/O registers are included to allow the 8x305 to control and monitor operation within the IPM. The address registers of the 8x305 are included in this block because they are addressed just as any other register and require a complete cycle to which to write. The 8x305 executes instructions from four 2K x 8 PROMs. The main function of the IPM is to accept commands from the 3270 interface, decode them and then issue the appropriate response. The display screen data that is passed to and from the IPM is kept in the SRAM screen memory array.

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Library Management Unit

When the IPM detects that a message has been received for the ACS, it transfers that message from screen memory to the LMU Bus Transmit function. This data is then sent to the CPM over the LMU Bus. An interval timer is included to allow the IPM to detect a loss of communication over the 3270 interface. If no communication is sensed for 1 second, the timer time-outs and flags an error. The FRU ID function is functionally separated from the rest of the IPM and may be accessed by the CPM only. The visual interface of the IPM card allows the service representative to quickly determine the IPMs that are enabled, which are in communication with a terminal control unit and which, if any, have any error status. Maintenance Procedures on page 3-1 contains card cage indicator tables and figures.

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Library Management Unit

Figure A-6. IPM (LC Card) Block Diagram

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Library Management Unit

RS-423 Interface Processor Module (NN CardUNIX Only)


The NN card is used only in the UNIX storage server to connect the ACS through a Sun workstation LAN to multiple non-IBM hosts. This connection to the Sun is at the LMU over RS-423 communication path(s). Figure A-7 on page A-13 shows a typical configuration using a single LMU. The LMU can have up to four RS-423 host interfaces (NN cards) rather than the typical 3270 interfaces (LC cards). Single Sun installations use one NN card, possibly with another as a redundant path. Dual Sun workstations could use up to four NN cards that are located in the motherboard Slots E1 through H1. The NN cards send and receive messages over the RS-423 to and from the Sun workstation. The Sun contains code that carries out a role analogous to the HSC. The LMU functional code is identical for both the 3270 or RS-423 interfaces.

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Figure A-7. UNIX Storage Server Block Diagram

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Figure A-8 on page A-15 shows the block diagram of the NN card. Major differences between the NN card and the 3270 IPM (LC) card exist in: Deleting the 3270 transmitter/receiver Deleting the read register 3270 external status Deleting the read/write register 3270 control Deleting the timer chip Removing the timer output from the 8x310 interrupt controller Removing the timer output from the green LED Adding the green LED to a software driven register Adding the 8530 ASCC Interfacing the 8530 through the old timer interface to the 8x305 Adding an interrupt from the 8530 to the 8x310.

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Figure A-8. IPM (NN Card) Block Diagram

Operator Panel (LD Card), Service Panel (MF Card)


The LD card is the operator panel card for the LMU. It contains the following circuitry: HPDL-2416 four-digit alphanumeric display on the LMU operator's panel. Light bars and LED displays on the LMU operators panel. These include PROC INACTIVE, PROC ACTIVE, MASTER LMU, SERVICE REQUIRED, and the status display.

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IPL and RESET switches on the LMU service panel. The switches

themselves are mounted on the MF card located behind the cover on the service panel. Alarm system. LAN indicators on the LMU service panel, which are located on the MF card.

Field Replaceable Unit Identification


Field Replaceable Unit (FRU) identification is provided in hardware for all logic cards and the motherboard. The identifiers can be read by diagnostic software executing in the CPM. The identification includes part number, card serial number, and EC level.

LMU Diagnostic Functions


Diagnostic functions supported in hardware include: 3270 interface wrap LAN interface wrap Data parity and checksums Data parity error forcing LMU bus buffer wrapping Nonmaskable interrupt source made software accessible Alternate RAM access through special instructions Software-controlled high and low, power and clock frequency margins Software-controlled power-down Software-accessible FRU IDs Real-time clock for error logging Hardware-detected events and errors: memory or bus parity, overtemperature warning (software-checked), and watchdog time-out

LMU Functional Responsibilities


The LMU operational functions are those that are explicitly requested by the HSC. The LMU interprets host requests and coordinates their execution on its LAN-attached LSMs. The level of communication from the host to the LMU consists of high-level requests to perform cartridge mounts and dismounts, movement of cartridges within the ACS, entering and ejecting cartridges into and out of the ACS, and control and status functions.

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The LMU translates host requests to move and mount cartridges into detailed LSM instructions for cartridge motions, gets, and puts. The LMU carries out LSM component resource allocation to assure both appropriate use and contention control of the components. It optimizes and coordinates movement of cartridges among LSMs. It manages the allocation, sequencing, and use of LSM resources (arm, hands, ports, and so on) to provide contention control for concurrent execution of host commands within a single LSM, and to control multiple LSM operations. Major functional responsibilities of the LMU are: LMU power-on and IPL LSM state control Host message routing Cartridge movement Cartridge access port (CAP) management Cataloging Unsolicited messages Status and performance reporting HSC recovery support

LMU Power-on and IPL


On LMU power-on, the LMU verifies that its processor and its immediate environment are working well enough to attempt the initial program load (IPL) from floppy disk. The initial hardware checkout is of a go/no go nature; it initializes, tests, and verifies the operation of the processor, PROM, RAM, timers, interrupts, and floppy disk drives. If diagnostic tests have determined it is incapable of functional operation, the LMU does not proceed, but requires service. Once the go/no go tests have been completed successfully, initial diagnostic software loads from the floppy disk. This software checks the full functioning of the LMU, including detection of both fatal and non-fatal errors and conditions, and initialization and testing of the RS-232 interfaces, host interfaces, LAN interfaces, and the operator panel interface. Once adequate LMU hardware operation has been verified, the entire functional software package loads from the floppy disk and is given control. The functional software resides entirely in memory and does not require access to the floppy disk. Maintenance and diagnostic programs require use of the floppy disk.

Dual LMU Init Logic Description


In a Dual LMU configuration, one LMU is configured during installation as the Master LMU (MLMU, LMUA) and the other LMU as the Standby LMU (SLMU, LMUB).

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Three specific cases exist for the initialization of the LMU(s): 1. An LMU is brought up standalone (single LMU configuration or other LMU is dead in DLMU configuration). 2. An LMU is brought up while the other LMU is functioning as an MLMU. 3. Both LMUs are brought up at approximately the same time. The initialization logic is as follows: When an LMU powers on, it assumes the role of a SLMU and sends out polls (SPOLLS) to determine if a MLMU exists. If another MLMU is not found, then this LMU assumes the role of MLMU. It then reports this status to the HSCs and adheres to the rule that an LMU cannot be brought up partially connected in a DLMU configuration. If the other LMU is already a master, the second LMU to be powered on receives a master acknowledgement (MACK) and assumes the role of Standby. If both LMUs are powered on at approximately the same time, both LMUs start sending out SPOLLs to the other. Each LMU sees that it is receiving and sending SPOLLs. Both LMUs recognize this as a tie, and LMUA assumes the role of MLMU; LMUB assumes the role of SLMU. If, during the SPOLL phase, one of the LANs is found to have a problem external to the LMU, the initializing LMU must take special action. Since this LMU cannot initiate communication on the broken LAN, it must continue its SPOLL phase for a period longer than the maximum time necessary for the other LMU (if it was an MLMU) to detect the LAN problem and switch to the good LAN. After this extended SPOLL period, this LMU has either received communication from the other LMU or goes to the MLMU state.

LSM State Control


The LMU supports HSC control of the state of an LSM. A state change effected by the HSC in one host is visible to all hosts. The online/offline state of the LSM is controlled by the Modify LSM Online/Offline HSC operators command. The HSC formulates a HSC/LMU transaction (Vary LSM transaction) to instruct the LMU to change the state of the LSM. This is not to be confused with the Vary Station HSC operators command which controls the on-line/off-line state of the Host Interface at the LMU. The Modify LSM command applies globally to all host central processing units (CPUs).

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An LSM that is offline to a host CPU is still available for manual mode operations (physical entry into the LSM), and for diagnostic requests from a host CPU for the offline LSM. The states of the LSM are: Offline Generally, the HSC is not allowed to issue any requests using the LSM except for a request to change the state to online. The initial state when an LSM is reset or IPLed is offline. When offline, all mechanical motion in the LSM is stopped. All other requests issued while offline are rejected, except as noted. The HSC is allowed to issue any valid request using the LSM. The host cannot initiate any new requests using the LSM except for a request to change the state to online. Outstanding requests are completed normally.

Online Offline Pending

A state change may be requested by the HSC without regard to the current LSM state, except while in offline pending state. A state change is requested with a Vary LSM request generated from the Modify LSM command, which changes the LSM state to: Online Offline The LSM goes online only if it is available for functional operation. If requests (from any host) that use the LSM are not outstanding, it changes to the offline state. Otherwise, if any requests that use the LSM are outstanding, it changes to the offline pending state. The LSM then goes to offline when all outstanding requests are completed. If another offline request is received while the LSM is in the offline state, that request is rejected. If an online request is received before the outstanding requests are completed, the LSM goes back online. The LSM goes offline to all hosts immediately without regard to any outstanding motion requests using the LSM. Such outstanding requests for the LSM are not preserved. The LSM internal state is changed to offline; however, any motion commands in progress in the LSM are not terminated, but allowed to complete.

Offline Force

An offline request will be rejected if a CAP reservation is in effect. To verify the enter or eject state of the LSM, issue an LSM Status Request. An offline force request will remove (without notification) any CAP reservation in effect. A Vary LSM response with the new (current) state returns when the LSM goes to the online or offline state. If another Vary LSM request is issued before a prior Vary LSM request has returned its response, the prior request still returns a

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response (with the original originator ID and sequence number) but shows that the request was overridden by a later request.

Host Message Routing


The HSC in one host may request transfer of a message through the LMU to the HSC on all hosts attached to the LMU. Message Route Request Sends request data to all other hosts. The response is a list of host IDs to which the message was successfully routed.

The data is transferred as unsolicited host-to-host messages.

Cartridge Movement
The LMU provides the control needed to manage cartridge movement commands to the LSMs. Movement commands may span LSMs or be limited to a single LSM.

Label Conventions
Cartridge optical character recognition (OCR) labels are those read by the LSM. Magnetically recorded internal tape labels are neither read nor used by the LMU or LSM but may be used to verify OCR labels by the HSC. All the following VOLSER references are to the volume serial number passed by the host to the LMU in a host request, and not to the magnetic label. It is generally presumed in cartridge move operations that the VOLSER corresponds to the OCR label; however, host requests to move cartridges contain a label modifier option to: Verify that the OCR cartridge label compares to the passed VOLSER Verify that the label cannot be read Ignore the label check completely Use the recovery cartridge number (in-transit identifier) as specified (mount and move requests only)

If the OCR label is to be ignored, or is verified unreadable, no attempt is made to compare the passed VOLSER to the OCR label on the cartridge; the VOLSER is retained internally as a token for recovery purposes only.

Location Conventions
The HSC identifies cartridge cell locations within an LSM and in a wall, the CAP, a transport, or by use of the recovery cartridge number (in-transit identifier). The HSC cannot identify the pass-thru port (PTP)/cartridge exchange mechanism (CEM) cells.

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The issuing host must have the CAP reserved to move a cartridge to or from a CAP cell.

Resource Allocation
The LMU is responsible for allocation and contention control of the LSM resources required to effect a motion command. These resources include: LSM arm and hands, the PTP/CEM mechanism PTP/CEM slots CAP or PCAP, transports An entire LSM (for online or offline state)

Allocation of a resource to a request execution assures that the resource is reserved to that execution until relinquished. Contention control is assured by allowing only one allocation of a resource at a time. All allocations are made on a first come, first served basis. With some of the following exceptions noted, a request execution waits for a resource that is already allocated to be released. Also, the LMU optimizes the usage of certain resources, especially path selection through multiple LSMs. The LMU maintains the dynamic configuration of LSMs: resources added to or removed from the system (for example, LSM going online or offline, or a redundant mechanism failing or becoming available). Host requests requiring resources in an LSM that is not online are rejected. Similarly, requests initiated from diagnostic sources are rejected unless the selected LSM is in maintenance mode. For host requests that require passing a cartridge from one LSM to another, or moving a cartridge to a transport or CAP, an entire slot path is allocated before any LSM motion commands are performed. A slot path is an optimized path through the minimum number of LSMs that connects the cartridge source to the final cartridge destination, and for which there is a non-allocated PTP/CEM slot in each of the connecting PTP/CEMs. That path, for the selected PTP/CEM slot(s), and source and destination cells (or transports), is allocated to the request execution. A slot remains allocated until it has been used and emptied; however, if the request includes a transport as its source or destination, the path is not released until the specified destination contains the cartridge. Any host request involving the CAP includes allocation of the CAP. The ID of the host making the request must match the ID of the host that has reserved the CAP; otherwise, the request is rejected. The CAP may be reserved by only one host at a time. No motion requests involving the CAP are accepted while the CAP is in enter or eject mode. Enter or eject requests are rejected if any motion requests are outstanding against the CAP.

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Before a request execution can initiate an LSM Motion command, it must receive allocation of any resources needed to complete that single command. These resources are necessary combinations of arm, hand, and PTP/CEM mechanisms. When the LSM command completes, the resources are relinquished. Some resources, such as an arm, are released at the end of each command that needs it, allowing other requests a chance to use it. Others, such as a hand holding a cartridge, can be retained across more than one LSM command.

Motion Requests
Cartridge motion requests include Mount, Dismount, Swap, and Move. Motion requests differ primarily in the source and destination of the cartridge. Requests to mount, dismount, or swap are rejected if the (source or destination) transport has a loaded cartridge; the transport might be in use by a host. Common recovery actions follow the request descriptions. Mount request Moves a cartridge from a cell and mounts it to a transport. The request is acceptable while a dismount (rewind and unload) for the same transport is pending completion. A Mount response is made when the cartridge has been mounted and readied on the transport. The number of LSMs (but excluding the source LSM ID) that are used in the cartridge move (through which the cartridge passes) is returned in the response. Dismount request Removes a cartridge from a transport and moves it to a cell. A rewind and unload issues to the transport (if requested in the source modifier, and if one is not already in progress). A dismount request is acceptable while a rewind and unload for the same transport is pending completion. A Dismount response returns when the cartridge has been dismounted and moved to the destination cell. The number of LSMs (but excluding the source LSM ID) that are used in the cartridge move (through which the cartridge passes) returns in the response.

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Swap request

Removes a cartridge from a transport and move it to another transport. A rewind and unload is issued to the source transport (if requested in the source modifier, and if one is not already in progress). A swap request is acceptable while a rewind and unload for the source transport is pending completion. The destination transport (unless the same as the source transport) must not contain a cartridge, either mounted or dismounted. A Swap response returns when the cartridge has been mounted and readied on the destination transport. The number of LSMs (but excluding the source LSM ID) that are used in the cartridge move (through which the cartridge passes) is returned in the response.

Move Request

Moves a cartridge from one cell to another. A Move response returns when the cartridge has been moved to the destination cell. The number of LSMs (but excluding the source LSM ID) that are used in the cartridge move (through which the cartridge passes) returns in the response.

Recovery of In-Transit Cartridges


HSC recovery action is required when a major LMU or LSM failure occurs. Cartridges being moved may have been left in the hands or PTP/CEMs. HSC detects such failures and initiates recovery actions when: An LMU Ready message is received (the LMU has just powered-up or been reset); or when An LSM Not Ready message followed by an LSM Ready message is received (the LSM has been re-initialized).

Recovery of any cartridge movement is possible by using any cartridge move request with the Read Transition Cartridges request. The HSC (in a host detecting that cartridge recovery is required) issues a Read Transition Cartridges request. The response provides a list of cartridges at in-transit locations: PTP/CEMs or hands. Mount or move requests can then be issued against this list of cartridges. Set the request source modifier to in-transit.

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Set the label modifier as follows: Verify VOLSER label Either Bypass label check or Verify unlabeled Recovery cartridge number specified For cartridges that had a readable label For cartridges whose label was unreadable and the token VOLSER was retained and returned with the Read Transition Cartridges Request response For cartridges for which no VOLSER data is available

In the last case, the LMU correlates the recovery cartridge number (in-transit identifier) with an internally maintained recovery cartridge list to identify the appropriate cartridge.

Recovery of Failed Motion Requests


If a failure occurs in a cartridge movement, the LMU attempts to re-route the cartridge through any other working paths. If this succeeds, a normal response returns to the host. If re-routing fails, the LMU attempts to return the cartridge back to its source (including transports) and returns the disposition of the cartridge in the error response. The disposition identifies where the cartridge was left and how it should be recovered.

CAP/Priority CAP Addressing


The standard 21-cell CAP on the standard access door and the two CAPs and Priority CAP (PCAP) on the optional 80-cell CAP access door are all considered to be mechanisms of one type. They are addressed as Type CAP with a CAP selector field. The CAP selector field shows the relative position of the CAP on the LSM. The CAP selector increases in the clockwise direction and from top to bottom. Since the 21-cell CAP is the only one on an LSM it has a selector field of 00. The optional door CAPs and PCAP all reside on the door (Panel 11) and are numbered from the right to left with CAP 0 on the right. CAP Selector Field 00 corresponds to CAP 0, 01 to CAP 1, and 02 to the PCAP. Within a CAP the cells are numbered by row and column. For the optional door CAP (CAP 0 or 1) the column is always 0 and the row varies from 0, at the top of the door to 39, at the bottom of the door. Depending on the number of magazines present the topmost usable cell is Row 0, 10, 20, or 30. The address of the single cell in the PCAP is always Row 0, Column 0.

CAP Management
The LMU supports HSC management of the CAPs for the operator. The LMU carries out CAP reservation for HSC in a requesting host to control potential

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host contention for the CAP. The HSC must request the LMU to reserve the CAP (to its host) to perform the CAP operations of entering cartridges into or ejecting cartridges from the LSM, and then release it on completion of those operations. The reservation and release pair apply to only the CAP selected and not to any other CAP, even those on the same LSM. At the LMU level, each CAP is operated independently of all other CAPs in the ACS. Each may be independently used for enters or ejects or may be idle. The CAPs are designed so they can be opened, closed, filled, or emptied by the operator without interfering with the robotic operation of the LSM. Other than motions to or from a specific CAP, cartridge motions are not affected by that CAPs operations.

CAP Reservation
Enter and eject requests and any motion commands to the CAP must be bracketed with reserve and release CAP requests: CAP Reserve request Reserves the CAP of the indicated LSM to the requesting host. The CAP remains reserved to the current host until a release CAP request is received. A CAP Reserve response return if the LMU is able to establish the requested reservation. The CAP must be operational and not be reserved from any prior request. If the CAP is already reserved, the ID of the host holding the reservation is returned in the error response. A current CAP reservation can be overridden for recovery purposes by specifying the override/recovery option. The current CAP reservation is broken and the CAP reserved to the requestor. CAP Release Request Releases reservation of the CAP in the indicated LSM from the requesting host. A CAP Release response returns only: If the requesting host holds the current reservation. If no enter or eject requests and no cartridge motion requests using the CAP are outstanding; however, if an enter request has been issued but the CAP door has not been opened, this restriction does not apply. When the reservation is actually released by the LMU

CAP Enter and Eject


After reservation of the CAP is established, enter, eject, and cartridge motion requests to or from the CAP can be issued.

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Entering cartridges requires the CAP enter operation followed by move or mount requests from the CAP. Ejecting cartridges requires moving or dismounting cartridges to the CAP, and then the CAP eject request. Although enter and eject requests can be mixed, it may be operationally desirable to limit the cartridge movement to only one type at a time. Enter or eject requests and move requests that address the CAP are rejected if the issuing host has not reserved the CAP. Enter operations consist of the following request and response sequences: Enter processing A CAP Unlock with the Enter option set causes the CAP door in the identified LSM to unlock. A CAP Unlock response returns when the CAP door has been successfully unlocked and can be opened by the operator. At the CAP, the CAP locked indication goes from locked to unlocked and the Enter indication appears. The CAP Unlock command has a CAP Reserve and a CAP Release option. For the CAP Unlock to be accepted, the CAP must be reserved. The reservation can be accomplished by setting the CAP Reserve option, or the reserve might have been done at another time. If the CAP Release option is set, the CAP is unlocked and then released before the CAP Unlock Response is sent. Any combination of the Reserve and Release CAP option flags may be used. If the Reserve option is set and the Unlock fails for any reason, the reservation is not in effect at the time the error response is sent. The CAP Open indication appears when the CAP door is opened. The operator can then enter magazines and/or cartridges. When the CAP is opened, a CAP Open message is sent to the owning host, or broadcast to all hosts if the CAP is not reserved to any host. When the CAP is closed, the door automatically locks, the CAP ENTER indication turns off, and the CAP LOCKED indication illuminates. The CAP Open indicator illuminates until the CAP is securely closed and latched. A CAP Closed message is sent once the CAP is closed and locked. If the CAP is reserved, the message is sent only to the host that has reserved the CAP. If the CAP is not reserved, the CAP Closed message is broadcast to all hosts attached. This message includes an indication of whether the CAP contains cartridges or not.

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The host software is responsible for cataloging the CAP and moving the cartridges out of the CAP using Mounts or Moves. If cartridges are cataloged that are unacceptable to the host (for example, unreadable bar code labels), the host can reject those cartridges by foregoing the move requests and instead issuing another Unlock request. The CAP Unlock request has an option for indicating on the operator display what the reason for rejection is. After the cartridges are removed, the operator can continue with normal enter operations. Successive enter operations are done by repeating the preceding process. Ejection processing The CAP must be reserved and locked before moving cartridges to the CAP for ejection. If the CAP is unlocked, this can be accomplished either by reserving the CAP and then at a later stage sending the CAP Lock, or the Reservation option may be included in the lock itself. Because the large CAPs in the optional door can contain between zero and four magazines, the number of cells available in a large CAP for eject can vary. Therefore, it is necessary for the host software to make a CAP Status request before beginning to eject. The CAP Status response contains a count of the number of cells available in the CAP. The host must then move cartridges into the CAP using the Dismount or Move request. After all cartridges have been placed in the CAP, a CAP Unlock with the Eject option set can be used to unlock the CAP for the operator. The operator can open the CAP, remove the cartridges and close the CAP. When the CAP is closed, the CAP automatically locks and a CAP Closed message is sent to the host. As with the Enter, these messages are directed at the host holding the CAP reservation or, if the CAP is not reserved, are broadcast to all attached hosts. After the CAP is closed, the CAP Closed message indicates to the host software, if known, whether all cartridges have been removed from the CAP. Cartridges that the operator inadvertently left in the CAP and were detected by the catalog can be ejected by issuing the CAP Unlock request again. A message may be placed on the CAP display by the host using an option in the CAP Unlock request. Successive eject operations can be done by repeating the Move or Dismount and the CAP Unlock requests.

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CAP Recovery
HSC recovery action is required when either a major LSM, LMU, or host software failure occurs or the LSM has been re-initialized (an LSM Not Ready message followed by an LSM Ready message). The HSC should: Issue the Read Transition Cartridges request as required under the general cartridge recovery scenario; and Issue the CAP Status request, to determine if the CAP is currently reserved. If reserved, and a host is recovering for another host, the CAP reservation must be changed from the old to the new host ID. This is done by issuing a CAP Reserve request with the Recovery modifier set to override/recovery, which breaks the current CAP reservation and reserves the CAP for the requestor. If no host reservation exists, any host can reserve the CAP and perform recovery. If any enter or ejects are in progress, but with the CAP door closed at the time of failure, no special recovery of those requests is needed now. Any cartridges in transition to or from the CAP can now be recovered by issuing cartridge motion requests with the Recovery (In-Transit) option. If the CAP door has been left open, the LMU still accepts normal CAP Unlock commands. After recovery has been accomplished, normal CAP requests can be issued to continue any other CAP operations.

Paired CAP Mode (80-Cell CAP)


In the 80-cell CAP Paired Mode, the old Enter/Eject Protocol is used. Some modifications to this protocol are necessary to support the paired 80-cell CAP. Missing magazines If magazines are missing, the host is notified that the LSM could not target on the CAP cells instead of reporting nonexistent cell, because this shows a configuration mismatch. The addresses of the CAP cells will be specified as a fixed Column 0, with the row varying from 079. The panel field will remain 0. The final Enter/Eject response contains the catalog of the CAP. Because that catalog is now 80 cells long, the response is being broken up into several intermediate and one final response.

Addressing

Enter/Eject Final response

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Open and Close responses

The intermediate CAP Open response is sent to the host when the first CAP is opened. No action occurs when the second CAP is opened. The intermediate CAP Closed response is sent to the host when the second CAP is closed. No action occurs when the first CAP is closed. There is a message on the display to show the CAPs are being operated in tandem mode so the operator know in which mode the CAP is being operated. The 80-cell CAP is operated as a single CAP. Any failure of either CAP is considered a failure of the CAP and is treated as such.

CAP mode display Recovery

Cataloging
Cell cataloging allows the HSC to verify actual cartridge contents of an LSM. The HSC uses catalog requests to initially build its cartridge database, to maintain it during recovery or operator access to the LSM, and to manage the CAP. Catalog request catalogs the cell contents (within a single LSM) of a full wall, a sub-wall (a range of cells within a single wall), a CAP, or a range of drives within a single LSM. Cells are cataloged sequentially in ascending column number within ascending row number. The CAP must be reserved and the CAP door closed to perform CAP cataloging; an error response is made otherwise. Cataloging of the cartridges is limited to only those cartridges that are unloaded. The CAP Catalog response is contained in zero or more intermediate responses and a final response that cover the requested cell range. Each response contains the status of a sequence of cells and the cartridge label (if available) in those cells. The cell status shows whether: A cartridge with a readable label was found A cartridge with an unreadable label was found No cartridge was found No cell exists at this position

All potential positions are cataloged even when occupied by CAPs or PTP/ CEMs. Multiple responses may be returned if the responses require more data than allowed in the transaction format. The intermediate responses (if any) and the final response contain the response count and the starting catalog address for the cell sequence in this response. For full wall catalog requests, only a beginning wall number is specified. The ending wall number and all row and column addresses are zero. The cell sequence in the catalog response is from Row 00, Column 00 to Column 23, to Row 01, Column 00 to Column 23, and so on, down to Row 14 for the outer wall and from row 00, Column 00 to Column 19, and so on, down to Row 14, excluding Rows 6 and 7.

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For sub-wall catalog requests, only a cell or cells within a single wall can be cataloged. The beginning address specifies the wall and the beginning row and column address. The ending address specifies the ending row and column; the ending wall number is 0. The ending row (column) must be greater than or equal to the beginning row (column). Wrapping is not supported (for example, from Column 23 to Column 0 or from Row 14 to Row 0). Only cells within the (beginning, ending) matrix are cataloged. The order of cells reported in the catalog response starts with the beginning row, beginning column to ending column, then the next row, beginning column to ending column, and so on, until the ending row has been cataloged.

Catalog Recovery
If a major failure occurs during the catalog request any prior intermediate responses are valid but further cataloging terminates. The host determines the positions that remain uncataloged and reissues the request with the new range.

Unsolicited Messages
Unsolicited messages are transactions (generally sent from the LMU to the HSC) that are not direct responses to an HSC request, but are indicative of events occurring at the LSM level. An unsolicited message from the LMU is sent to all hosts attached to the LMU. Of the following messages, only the Door Opened message requires a message acknowledgment from the recipient host. Error message Host to Host message Clean Drive message Door Opened message Describes errors that have occurred within the LSM or LMU, but have not caused a hard failure. Transfers data to other hosts as described by the Message Route request. Shows a drive that has requested cleaning. Shows the LSM whose access door was opened. This event is preserved despite the LSM going offline or a loss of LMU or LSM power until a message acknowledgement is received from the host. Shows the host has received the Door Opened message. Returns the LSM ID of the door that closed.

Door Opened message acknowledgment Door Closed message

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LSM Ready message

Shows an LSM that became ready, which means that the LSM has been powered-on, has been initialized for functional use and is not in maintenance mode. This message returns regardless of the LSM offline/ online state. Shows an LSM that became not ready, which means that the LSM has become inoperative. This message returns regardless of the LSM offline/online state. Shows an LMU that became ready, which means that the LMU has powered-on, has been initialized for functional use, and is not in maintenance mode.

LSM Not Ready message

LMU Ready message

Status and Performance Reporting


Status reporting is supported for both operational status management and diagnostic analysis of component performances.

LMU Status request

Requests to return the status of the LMU station(s) (installed, operative, preventative maintenance required). Requests the status of the indicated LSM and its components, including: LSM ready mode LANs (operative) Hands (operative, preventative maintenance required, cartridge presence) CAP (operative, CAP door opened, reserved and reserving host) Access door (open) Drives (available, cartridge presence, cartridge loaded, ready, cleaning required) PTP/CEMs (operative, preventative maintenance required, cartridge presence per PTP/CEM cell).

LSM Status request

Read Configuration Request

Allows the HSC to verify the ACS configuration. The LSMs can be either online or offline for this request. The response to this last request is the configuration of LSMs, their wall types, and the PTP/CEM connectivity: the static configuration that was entered by the service representative.

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The HSC automatically compares this static ACS configuration to that specified in the LIBGEN when the LMU station is brought online. If these configurations are inconsistent, the HSC automatically returns the station to an offline status and issues an error message to the operator console. The wall-type information might be erroneous if an LSM has not yet been initialized. Note that: The LMU does not complete initialization if the static configuration file is absent An LSM is not allowed to complete initialization if the LMU finds that the static LSM configuration does not match the actual LSM configuration

The sequence of two or more intermediate responses and a final response is The LSMs that are actually configured A list of the PTP/CEMs configured in the ACS. The response is variable in length on the basis of how many PTP/CEMs exist. Each PTP/CEM is uniquely identified by the master LSM ID and its wall location in the Master, and the Slave LSM ID and its wall location. Later wall configuration responses are returned for each LSM that was shown configured in the initial response. A type code is shown for each of the outer walls. Read Transition Cartridges request, that specifies an LSM for which recovery is required. The specified LSM must be in the ready state. The response contains a list of cartridges that were found in transition on a power-on of an LSM, LMU, or both. A cartridge is defined to be in transition when found in the LSMs hand or master PTP/CEMs. Mounted cartridges are not reported as in-transit; they might be in use by the host. Dismounted cartridges are not reported as in-transit; they may be handled directly by HSC dismount or swap requests. The HSC can determine the status of all drives through the LSM status request. For each cartridge, the label status and label are returned. The label status shows: A readable label was obtained An unreadable label was found, but the token VOLSER originally issued with the request was preserved An unreadable label was found but no token VOLSER was preserved

In the last case, the LMU assigns an internal recovery cartridge number (in-transit identifier) to the cartridge for later identification purposes.

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Read Cartridge Status request

Shows when an LSM cartridge motion command is completed. The request can be made by any host, regardless of which host initiated the motion. If the indicated cartridge is not found active, the response indicating such is returned immediately. If it is found active, the response is returned when all motion completes against the cartridge. The In Motion status is based on completion of the robotics and is not on successful completion of the original motion request.

ACS Statistics request

Transfers ACS statistics and optionally resets the statistical counters. Statistics recorded are percentage arm utilization, PTP/CEM connectivity and PTP/CEM passed cartridge counts for each LSM. Multiple responses return: The first response contains the monitoring period start time (the time at which statistics were reset) according to the LMU time-of-day clock, and a map of which LSMs are actually configured. Later, individual responses containing statistics for each LSM shown in the initial response.

Statistics are reported only on mastered PTP/CEMs. The data are all zero for PTP/CEMs that are not installed.

HSC Recovery Support


To assist the HSC in recovering after a host failure, the HSC may cause selected ACS activity to terminate or complete, and then assume communications from the LMU to the failed host. HSC on one host can recover from its own host's failure, or can recover for HSC on another host. Acquiesce Host request Brings any outstanding activity for the designated host to its normal completion point. Immediately on receipt, any messages or responses for the designated host that were unable to be successfully transferred to that host are purged. The host path group is not modified by this request. The LMU waits for all additional requests still in progress for the designated host to complete, then returns the quiesce host response. Responses from those requests in progress are discarded by the LMU. Any CAP reservation by the designated host must be overridden by the requesting host using CAP reservation with the override/recovery option.

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While the quiesce host request is active: No other quiesce host requests can be issued against the designated host No other types of requests are accepted from the requesting host Any requests from the designated host (regardless of the station they might be received over) are rejected Requests from other hosts are accepted in the normal fashion.

If another failure occurs (that is, the requesting host) while a Quiesce Host request is active, another Quiesce Host request can be sent with the override option specified. The original request is rejected with an error response; the overriding one proceeds. A Quiesce Host request with the Override option received when no other Quiesce Host request is active is accepted as a normal request.

Library Control Unit


The library control unit (LCU) provides microprocessor control of the LSM components and functions. It: Interprets instructions received from the LMU Directs execution of LSM component functions (through the appropriate interface) Maintains status information for the LSM to be reported to the LMU.

Figure A-9 on page A-35 is a block diagram of the 4411/4410 LCU/LSM. Figure A-10 on page A-36 and Figure A-11 on page A-37 are detailed block diagrams of the 9311/ L5511 LCU and the 9310/L5510 LSM.

LCU Functional Components


The LCU is a microprocessor based controller including the following functional parts: Central processor module Pass-thru port control Interrupt timer Camera/solenoid REI/theta interface Theta servo Operator panel, service panel FRU identification

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Figure A-9. 4411/4410 LCU/LSM Block Diagram

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Figure A-10. 9311/L5511/9310/L5510 LCU/LSM Block Diagram (Sheet 1 of 2)

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Figure A-11. 9311/L5511/9310/L5510 LCU/LSM Block Diagram (Sheet 2 of 2)

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Central Processor Module (LZ/PLZ Card)


The LZ (4411) card, located in Slot C2, is the processor card. It contains: A Z8002 microprocessor The LAN interface for the LCU The camera data storage circuitry PROM (used for power-on, initial hardware check, initial boot code, and diagnostics) 512K of static RAM (used for full IPL code and functional and diagnostic code and data)

The operator panel interface and the circuitry used for frequency margining. Figure A-12 on page A-39 is a block diagram of the LZ card. The PLZ in the 9311/L5511 LCU replaces the 4411 LZ card. The LCU motherboard is the same in both models. The PLZ card has A 32 MHz DSP chip A sequencer to handle the interface to the Z8000-bus motherboard 256K words (32 bits each) of 0 wait-state RAM 32K words of 2 wait-state flash EEPROM Two ethernet interfaces with local DMA memory A vision interface which uses the processor DMA capability Miscellaneous logic control, status, and error reporting.

The processor RAM is data protected for at least two days by two 1.2 V NiCad rechargeable batteries. Two LAN connections on the LCU attach the LCUs to the LMU. The LAN cables connected to the LMU and LCU BNC connectors are 50- coaxial cables and duplicated to avoid a single point of failure. The LMU selects the LAN to be active. Data transmits as packet data in a frame format. The frame is a byte sequence of the preamble, start frame delimiter, destination and source address, packet length and data, and CRC field.

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Figure A-12. CPM Block Diagram (4410 LZ Card)

Pass-Thru Port Control (LP/LPP Cards)


LP(P) 0 and 1 cards, located in card cage Slots A2 and B2 respectively, control the Master PTP/CEMs 0 and 1 installed in the LSM. If only one PTP/CEM is installed, it is PTP/CEM 0. For each Master PTP/CEM there must be an LP(P) card in the LCU card cage. Figure A-13 on page A-40 is a block diagram of the LP card.

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Figure A-13. 4420/L5520 Pass-Thru Port Block Diagram (LP Card)

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Interrupt/Timer (LY Card)


Figure A-14 on page A-42 is a block diagram of the LY card. The LY card located in Slot D2 of the card cage contains: The interrupt and timer circuitry (support logic) CD interface control Power-down request logic Voltage margining request logic LCU watchdog timer The interface control circuitry for the RS-232 maintenance and utility ports

Two asynchronous serial communications interfaces are supported by the LW and LY cards. Baud rates of 300, 600, 1200, 2400, 4800, and 9600 are software-selectable. These interfaces are intended for attachment of a maintenance computer or dumb terminal. The interface connectors are female D-25 connectors wired as RS-232C DCE in conformance with the UUT/392X Interface Definition. The diagnostic port displays diagnostic messages generated from a maintenance computer attached to the LMU.

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Figure A-14. Interrupt/Timer Block Diagram (LY Card)

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Camera/Solenoid (LW/PLW Card)


The LW card, located in Slot F2 of the card cage, contains: The camera analog-to-digital (A-to-D) converter Camera diagnostic circuit Solenoid driver circuit Environmental A-to-D for the 13.5 V Video threshold DAC reference and output Camera circuit 5 V LX A-to-D reference

Figure A-15 on page A-44 is a block diagram of the LW card. The PLW card is the replacement card in the 9311/L5511 for the 4411 LW card. It performs the same basic functions as the LW card and also allows text and graphics to be displayed over the camera view on the video monitors. The major functions of the LW and PLW cards are: Solenoid drivers and associated sensing/protection for the CAP lock/unlock solenoid and the has been opened (HBO) switch solenoid. Video capture for processing by the LZ/PLZ card. The analog video from the camera is converted to a bit stream and horizontal and vertical syncs. The monitor overlay function (PLW card only) allows text and graphics to be displayed over portions of the video monitor output. The overlay replaces a portion of the cameras view and the remainder of the picture is from the camera. Both monitors show the same size overlay, but each monitor has its own overlay memory, so the monitors could show different information.

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Figure A-15. Camera/Solenoid Block Diagram (LW Card)

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REI/Theta Interface (LX/PLX Card)


The LX/PLX card located in Slot E2 of the card cage contains the: REI and theta interface System resets Access door/CAP door sensor interface Environmental A-to-D for LCU 5 V LCU DAC reference and output Temperature sensors 5 V sensor LW A-to-D reference Temperature reference voltage Hardware reset 2.5 V reference

Note: The PLX card is used with the duplicate AC power cord supply and new DC supply. It contains a cable that runs from the PLX card to J526 on the DC supply. Voltage errors are reported through this cable. Figure A-16 on page A-46 is a block diagram of the LX card.

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Figure A-16. REI/Theta Interface Block Diagram (LX Card)

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Theta Servo Card (LQ/PLQ Card)


The LQ (4411) or PLQ (9311/L5511) card is mounted vertically on the righthand side of the unit as viewed from the front of the LCU. Figure A-17 on page A-48 is a functional block diagram and Figure A-18 on page A-49 is a connector block diagram of the LQ card. The hardware on this card translates motion commands from the LX card into current profiles to drive a permanent magnet, brush type DC motor which rotates the theta axis. Figure A-19 on page A-51 is a functional block diagram of the PLQ card.

Theta Servo (LQ Card)


The LQ interface to the LX card is an 8-bit plus parity, bidirectional, differentially driven system. The outputs of the transceiver circuits form a bidirectional data bus on which port addresses and read and write data are multiplexed. Control signals from the LX card are received differentially for noise immunity. These signals reflect Z8002 MPU timing that is critical for proper synchronization with the LX and LZ/PLZ cards during read and write cycles. Parity is checked at the theta card end of the interface. Parity error is latched as a fault condition. This fault is shown on a dedicated line transmitted back to the LY card. Parity error is also posted in the status register. Parity errors shut down the power amplifier and open the dynamic brake relay. Forced parity error is accomplished by a command from the processor through the LX card. The theta encoder on the 4410 theta drive motor is a 400-line, two-phase, incremental type. Theta encoder pulses are translated through a programmable array logic (PAL) state machine into count/down pulses. These increase and decrease three cascaded 8-bit counters for a total of 24 bits of positional information. Noise errors are detected by the encoder PAL and latched. The encoder pulses are buffered differentially for improved noise immunity. The encoder driver circuitry is located on the MC/MC1 card mounted to the theta base. Three radial position switches provide a logic-level indication of absolute theta position. The home position switch provides a position reference at initialization. The CW and CCW limit switches provide a logic level of radial overtravel in the CW and CCW directions. The theta limit switch override circuit incorporates a watchdog type timer so that CW and CCW limit switches can be contacted under servo control. This is permitted only for a short duration, as contacting these switches shows a loss of servo control with resultant shutdown under normal operating conditions. There are several fault conditions which, if detected, will immediately turn off the theta power amplifier and open the dynamic brake relay. These include a reset to the LQ card, a high current fault, power unsafe (+13.5 V, -13.5 V, or +5 V too low), an interface parity error or either the CW or CCW limit switches being contacted.

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Figure A-17. Theta Servo Block Diagram (4411 LQ Card) (Sheet 1 of 2)

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Figure A-18. Theta Servo Connector Block Diagram (4411 LQ Card) (Sheet 2 of 2)

Theta Servo (9311/L5511 PLQ Card)


The PLQ card is used in the 9311/L5511 LCU and is not interchangeable with the 4411 LQ card. See Figure A-19 on page A-51 for a block diagram of the PLQ card. It is a 24 kHz switching, high current (15 A), high voltage (100 VDC), brushless three-phase 56-pole theta motor driver card. The card is essentially a voltage amplifier with digitized bidirectional current sense available. It returns absolute position of the motor by counting incremental position information coming from a 25,000-line quadrature optical encoder mounted on the motor. Communication to and from the PLQ card is on the theta bus. Commands originate on the PLZ card and are transmitted through the LX card onto the 8-bit theta buss to the PLQ card.

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The 9310/L5510 theta motor is a digitally driven three-phase, permanent magnet, high torque, brushless DC motor. The output of the PLQ card drives the phase stator windings (A, B, and C) of the motor, which are physically located in the motor housing. The permanent magnet poles are located in the rotor, thus eliminating the commutator. Commutation is achieved by sequentially driving the phase connections of the motor (A, B, and C) in 12 steps. The following is an example of the first three steps of commutation: A+, B-, (- is DCC) A+, B-, CA+, C-

These driver signals for the motor are pulse width modulated at 24 kHz to reduce the effects of power supply (+100 V) variations, and to implement velocity control of the theta mechanism. Much of the circuitry has been incorporated into a field programmable gate array (FPGA) chip. In addition to reducing the number of components on the board, it also provides flexibility in the card-resident wakeup tests. The chip is reprogrammed at power-up time over the theta bus. The driver transistors are high power MOSFETs connected in a three-legged power H switch configuration. The FPGA contains these functional blocks: 20-bit position counter Theta interface logic Commutation counter PWM logic Status registers A/D conversion state machine Command register Watchdog timer Error collection/shutdown.

Other logic not within the FPGA is parity-checked for the theta buss and logic for downloading the FPGA. The PLQ contains fault checking and fault shutdown. The supply voltages are checked for undervoltage and the 100 V is checked for overvoltage. There is a top-side current trip if the 100 V supply current exceeds a preset limit. Due to the nature of accelerating and decelerating a motor, energy is stored in the motor during acceleration and returned to the supply during deceleration. This gives rise to a phenomenon known as pump-up; that is, the supply voltage is pumped-up during deceleration. To prevent this from occurring, an anti-pump-up circuit is added to the card, which loads the supply resistively when the voltage exceeds a trip point.

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Figure A-19. Theta Servo Block Diagram (9311/L5511 PLQ Card)

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Theta Sensor (9310/L5510 PMC) Card


The PMC card is used in the 9310/L5510 to interface the theta motor rotation sensors and theta tachometer with the PLQ card in the 9311/L5511, as well as providing an emergency power-off (EPO) signal to the power supply in event of extreme theta over-rotation. Two sensors are employed on the theta turns counter, one for indicating overrotation in the counter-clockwise direction (CCW) and the other for indicating over-rotation in the clockwise direction (CW). Combinations of the sensors may cause dynamic motor braking (DBR) or EPO. However, the EPO region is protected by a shear pin that requires approximately 500 ft.-lb of motor torque to shear. This amount of force would not likely be applied by an operator/service representative when rotating the robot by hand. The shear pin is designed to break only under extreme failure conditions. The EPO signal is created by the logic state of the two sensors. During normal travel, both sensor outputs are low. If either sensor (CW or CCW) output state changes to high, DBR is applied in that direction (unless overridden). If both sensor output states go high, the theta will EPO after the shear pin breaks. Tachometer signals are buffered and sent to the PLQ card in RS-422 format. The tachometer is an incremental device having normal and quadrature outputs. Clockwise rotation indicates the normal output leads the quadrature outputs. Home is a once per revolution signal. Tach_fail indicates the LED has become marginal.

Operator Panel (LR Card), Service Panel (NB Card)


The LR card is the operator panel card for the LCU. It contains the following circuitry: HPDL-2416 four-digit alphanumeric display on the LCU operators panel. Light bars and LED displays on the LCU operators panel. These include OFFLINE, ONLINE, MAINT MODE, LSM ACTIVE, PROC INACTIVE, PROC ACTIVE, SMOKE DETECT, SERVICE REQUIRED, and status.
IPL and RESET switches on the LCU service panel. The switches are

mounted on the NB card located on the side of the LCU near the top of the unit. Lan indicators on the LCU service panel. Thumbwheel switch interface. This selects the LSM within an ACS and is located on the LCU CSE service panel.

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Field Replaceable Unit Identification


Field replaceable unit (FRU) identification is provided in hardware for all logic cards and the motherboard and is read by diagnostic firmware. The identification includes part number, card serial number, and EC level.

LCU Diagnostic Functions


Diagnostic functions supported in hardware include: LAN interface wrap CD interface wrap Data parity and checksums Data parity error forcing Internal bus buffer wrapping Non-maskable interrupt source made software accessible RAM access through I/O instructions Firmware controlled high and low power and clock frequency margins Firmware controlled address compares Firmware controlled power-down Firmware accessible FRU IDs Real-time clock for error logging Hardware-detected events and errors (memory or bus parity, address compare, over-temperature warning, watchdog time-out)

LCU Functional Responsibilities


The LCU is responsible for physically and electrically managing the LSM. Major functional responsibilities of the LCU are LSM power-off LSM power-on, IPL, initialization LSM state control Configuration and status reporting Motion commands CAP commands PTP/CEM command Access door command Transport commands Unsolicited messages

The following sections provide descriptions of the LCU firmware functions.

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LSM Power-off
When the LSM is powered-off, the arm, turntable, hands and PTP/CEMs are moveable by an operator or service representative. Fingers closed on a cartridge do not drop the cartridge; however, the cartridge may be removed if needed, by an operator (but more likely, by a service representative). A cartridge cannot be manually placed in the fingers. The LSM access door may be opened. The door mechanism registers an opening for later logging and reporting when the LSM goes online.

LSM Power-on, IPL and Initialization


On LSM power-on or when the IPL switch on the LCU is pressed, the LCU verifies that its processor and its immediate environment are working well enough to attempt initial program load (IPL). The initial hardware checkout is of a go/no-go nature that has limited error isolation capabilities. It initializes, tests, and verifies the operation of the processor, PROM, RAM, timers, LAN, and interrupts. Once the go/no-go tests complete, the LSM awaits communication from the LMU over either LAN. With communications established, the LSM requests download of intermediate diagnostic firmware, and then functional firmware from the LMU (from the LMU floppy disk) over the LAN. IPL is controlled by the diagnostic/boot process. It is initiated by an LSM unsolicited message requesting the boot file list, then requests for the specific files. IPL code is downloaded by receive download commands from the LMU. When IPL is complete, the LSM (on the initialize command from the LMU) initializes itself, then becomes operational but not ready for use by the host. The LSM initializes the robot, determines the wall types, locates and reads the OCR label of any in-transit cartridges, then enters the offline state. LSM initialization is aborted if either the LSM access door or the CAP door is open. The Initialize LSM command requests the LSM to initialize the electrical and mechanical portions of the LSM that are not initialized before the functional code download. This command can only be executed if the LSM has been placed offline or is in maintenance mode. The LSM: Initializes the various servo mechanisms Determines the wall IDs (which includes master or slave PTP/CEM identification) for the physical configuration Carries out servo and location calibrations Locates and reads the labels of any in-transit cartridges (in hands, playground, or master PTP/CEMs) and Verifies CAP door status

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Initialization ending status shows if the LSM is working perfectly, is working in an impaired state, or is unable to function properly. In recovery from an offline or power-off state, cartridges may be present in either or both hands. These cartridges are stored in the reserved (playground) cells. The LMU may determine those when it requests the in-transit cartridges list. Also, error codes are returned for any errors that may have occurred during initialization.

Quick Initialization
When the IPL switch on the LMU is pressed or the LSM access door is opened and closed, the LSM performs what is called a quick init. During the quick init, an initialization bit state is checked for each servo mechanism. If the bit is set, the sequence continues until each mechanism is checked. If a bit is not active, only that servo mechanism initializes. The robot then moves to the playground on the LCU wall and checks for in-transit cartridges in Row 6, Columns 0 and 1. Any master PTPs/CEMs are also checked for in-transit cartridges. If any in-transit cartridges are found they are reported to the host and host software handles the movement of them. If the LSM has been opened and the access door is closed, the same action as the previous one occurs with one addition: after the LSM access door has been closed, the theta arm starts a slow sweep checking for any obstruction that may be in the arms path. If an obstruction is found, the robot will be disabled by the dynamic brake relay circuitry and power is removed from the servo amplifiers. The quick init reduces the time from approximately 12 to 2 minutes, depending on the number of PTPs/CEMs and whether the door to the LSM was opened and closed.

LSM States
The LSM states are: IPL Required Door Open IPL Complete Offline Online Maintenance Mode After power-on and if the initial go/no-go diagnostics are successful, or if severe hardware failures occur The LSM access door is open Successful IPL, or a door was closed after being opened and a previous IPL had been completed After an Initialize command or modifying the LSM to offline After modifying the LSM to online After modifying the LSM to maintenance mode

The (post IPL) state can be externally controlled by the Modify LSM command. A Modify LSM command varies the LSM state to online or to offline mode. The LSM can only be placed online when it has had its functional code downloaded

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and has been initialized. The LSM may only be placed offline when no command is active. The LSM must be placed offline before opening the access door. It must also be placed offline when a Detached Diagnostic Device or laptop is connected to the LMU maintenance port and the Select command is issued (to enter the maintenance mode) to run diagnostic tests. The LSM operator panel indicators reflect the actual LSM state. The commands allowed within each LSM state are generally: IPL Required Door Open IPL Complete Offline Download None Initializes and resets the door opened indicator and some components of request LSM state Generally any command that does not require robotic movement: Vary, Request State, Request Configuration, Request In-Transit Any commands except Vary to Maintenance Mode, Download, and Initialize Any commands except Vary to Online

Online Maintenance Mode

Configuration and Status Reporting


The LMU may request configuration and status information from the LSM through the following commands: Request LSM Configuration command Sends the configuration to the LMU. The information returned describes the physical layout of the LSM for its 12 outside walls. Each wall description includes the wall type. Requests the LSM to send the in-transit cartridge information to the LMU. Sends the current state (or some specified part of it) to the LMU. This command can be executed at any time.

Request In-Transit Information command Request LSM State command

Motion Commands
The meaning of motion commands, in the larger sense of storage cell management and coordination among LSMs, resides in the HSC and LMU. The LSM only carries out the command details, which are mostly physical controls. All motion commands specify a hand for positioning, grasping or camera (label reading) use. Attempting to access an absent cell will result in a target not found response. A response is made only when the command is completed or failed (after retries).

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Motion commands are: Move Arm Only Moves the specified hand from its current location to a destination location. The destination location is a specified storage, CAP or PTP/CEM cell, or a transport. Moves to a specified location and reads the OCR label of the cartridge; if the label matches that provided by the host, then it extends the specified hand and grasp the cartridge at that location. The LSM makes movement provisions for the type of destination (cell or transport). After the cartridge has been grasped, the hand retracts to its normal moving position. The status of the label read (no cartridge, good read, partial read, or bad read) and the OCR label returns to the LMU. Move and Put command Moves to a specified location, extends the specified hand, and releases the cartridge currently held into the destination. The LSM makes movement provisions for the type of destination (cell or transport). After the cartridge has been released, the hand retracts to its normal moving position. Moves to a specified location, and reads the cartridge OCR label at that location. The LSM makes movement provisions for the type of destination (cell or transport). The status of the label read (no cartridge, good read, partial read, or bad read) and the OCR label returns to the LMU. Returns the arm and hands to their appropriate home positions. If either or both of the hands contain cartridges, that fact is reflected in the ending status. This command is normally requested by the LSM (but issued by the LMU) following a period when the theta arm is idle. During the time allotted to this command, the LSM is free to execute internal diagnostics and/or recalibrations.

Move, Read and Get command

Move and Read Label command

Go Home command

CAP Commands
CAP management is handled by the HSC and LMU; however, physical CAP control and monitoring are done by the LCU.

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Set CAP Mode command

Sets the CAP mode to enter, eject, or idle. In enter mode, cartridges can be migrated into the LSM. In eject mode, cartridges can be removed by an operator from the CAP. In idle mode, the CAP door is locked and operator access is not allowed. The LSM posts the CAP status to the CAP operator or display panel, depending whether the standard or optional access door is installed. Locks the CAP door so that an operator cannot open it. If the CAP is already in enter mode and the door has not been opened, the enter mode prematurely terminate.

Lock CAP Door command

Unlock CAP Door Unlocks the CAP door so that an operator can open it. The command CAP door can only be opened if the CAP is in enter or eject mode. CAP door opening and closing events are reported as responses to this command. When the CAP door is closed it is automatically locked.

PTP/CEM Command
PTP/CEM management resides entirely within the LMU. Motion commands put cartridges to or get cartridges from the PTP/CEM. Physical PTP/CEM control is done by the LSM. Rotate PTP command (4420/ L5520 only) Activate Push Bar command (9320 only) Moves the specified PTP to the desired position (PTP cells facing into the master LSM or into the slave LSM). Moves the specified CEM push bar to the desired master or slave position.

Access Door Commands


Commands do not exist to operate or control the LSM access door; however, the LSM logs and reports all manual access door openings and closings. Even when the LSM power is off, the access door mechanism registers a door opening. When the LSM power is restored, the event is logged and reported. On command from the LMU, the LSM can reset the mechanism that shows that the LSM access door has been opened. The Reset Door Opened Indicator command resets the mechanism which shows that the access door has been opened. This command can be executed at any time. LSM initialization aborts if the door is open.

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Transport Commands
Some transport operator actions can be simulated by the LSM. These actions may be explicitly commanded by the LMU: Retrieve sense words Rewind and unload Set hold-off-load Reset hold-off-load Reset transport Blank transport display Diagnostic echo, and Request time until unloaded

The LSM normally loads a tape into a transport as an implicit part of an LMU command to move a cartridge to a transport. However, the HSC must explicitly requests an unload; a cartridge move from a transport requires that the tape already be unloaded. Only the following transport command sub-functions are explicitly used by the LMU: Rewind and Unload Transport command Notifies a library transport that it must rewind and unload. The LSM responds to this command when the transport has become unloaded and is ready for dismount. If the transport is unloaded or is already in the process of being unloaded, the LSM does not reject this command; rather, it simply responds when the transport is ready for dismounting. Responds with the expected time that elapses before a specified transport unloads. If the transport already contains an unloaded cartridge, the time will be zero.

Request Time Until Unloaded command

Unsolicited Messages
Unsolicited messages are packeted transmissions initiated by the LSM that are not in direct response to an LMU command, but reflect changes in the LSM state or operational conditions. Unsolicited messages are acknowledged, but do not receive a response. Such messages are: Access Door Opened and Closed Sent when the access door to the LSM has been opened or closed. Opening the door causes all power to be removed from the moving parts of the LSM.

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Request To Go Home

The LSM wants all the servo mechanisms within the robot to go to their respective home positions. This request is issued after some period when the arm is idle. This request must eventually be honored by the LMU, and a go home command is issued. Sent on a change in operational status of arm, hands, CAP, or master PTP/CEMs. No specific operation is required. Shows that a mechanism is failing or tending to fail. Sent when the CAP door has been normally opened or closed, or if the CAP is forced opened without being unlocked by the LSM. If a CAP lock request is received and the CAP is already in enter or eject mode, this message notifies the LMU that the previous CAP lock request is superseded. The task ID of the previous lock request is provided. The LSM IPL is completed. Refer to the Automated Cartridge System Diagnostic Users Guide, PN 88555.

Operational Status Change No Operation Preventive Maintenance Required CAP Door Opened, Closed, and Illegally Opened Enter/Eject Cancel

IPL Complete Diagnostic messages

LSM Idle Activity


The LSM carries out miscellaneous automatic mechanical maintenance when activity is not required of it by the LMU. This includes: Resetting mechanisms into rest or home positions Reducing servo and lamp current requirements Performing recalibration or detail cell calibrations Performing diagnostic motions Attempting to restore mechanisms reported inoperative because of positioning (or other) error trends, but that have not experienced a hard failure Updating non-volatile RAM logs Updating LMU (floppy disk) statistical logs

To perform such actions, the LSM sends a request to go home message to the LMU. The LMU then commands the actions, rather than having the LSM initiate them unilaterally. In this way, the LMU is aware of the resource requirements,

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LSM state, and granularity of the activity (for host request response time control).

LCU-LSM Interfaces
The internal interfaces between the LCU and the LSM are listed here to help clarify the division of logic and function between the LCU and LSM: Remote electronics interface (REI) The communications path between the LCU and electronics mounted on the rotating arm. This path provides: Cartridge access port interface Theta mechanism interface PTP/CEM interface A means of reading and writing registers on the arm electronics Transfer of camera data Power to the remote electronics

Provides control access to the CAP(s). Provides LCU (LQ/PLQ card) connection to the theta motor and sensors. Provides connection between LP card (4420/L5520 operation) and the LPP card (9320 operation) in the LCU motherboard to PTP/CEM components.

Library Storage Module


The library storage module (LSM) contains the storage cells and the accessing robot for the cartridges stored in the LSM. The LSM physically consists of two coaxial cylindrical walls (inner and outer) of modular walls containing the cartridge storage cells. A cartridge-handling robot is set in the center of the LSM and operates between the two walls. The robot is capable of locating cells, extracting and moving cartridges, and inserting cartridges into other cells or transports. The LSM contains the following major components: Cartridge storage cells, shelves or slots on the walls Cartridge access port (CAP), cartridge exchange with the operator Pass-thru port (PTP)/cartridge exchange mechanism (CEM), cartridge exchange with adjacent LSM Robot, which comprises: Arm assembly, cartridge-locating mechanism Theta mechanism, rotation to wall and cell column

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Z mechanism, vertical motion to cell row

Turntable assembly, hand rotation from inner to outer wall Hand assembly, optics and cartridge grasping mechanisms: Roll mechanism, vertical to horizontal (cell to transport or optional door CAP/PCAP cell) Reach mechanism, cartridge extraction and insertion Gripper mechanism, cartridge holding Camera assembly, cell target location and cartridge label reading

Calibration modules, robotics calibration areas Access door, for physically entering the LSM for operator or service personnel

Other than the CAP and access door, the LSM manual controls, displays and indicators are located on the LCU. These components are described in Chapter 2, Controls and Indicators.

Walls and Cells


The outer wall contains 12 walls; the inner wall contains eight walls. Walls vary in type and cell capacity depending on physical interface requirements. Cartridges are stored in the LSM in cells located inside the outer walls and outside the inner walls. Outer walls provide storage of cartridges in a 24 column-by-15 row array of cells (numbered 014). Inner walls provide 20 columns by 13 rows (numbered 014) with Rows 6 and 7 missing because of both the smaller inside wall diameter and the space needed for rotation of the robots arm assembly. Some walls are limited to less than the full cell array to provide room for the various physical interfaces: cartridge drives, library control unit, cartridge access port, PTP/CEM, power supply interfaces, and door hinges. The 9310/L5510 has an optional window wall with a capacity of 72 cartridges and provides viewing of the LSM robotic operation. Walls are identified by a wall type. Wall types are used to verify the LSM static configuration created by the service representative at installation time. Wall type information is determined by the LSM from wall ID cells that are permanently attached pseudo-cartridges at fixed wall locations. Those pseudo-cartridges have a reserved (invalid for customer use) OCR label that identifies the wall type. Partially populated walls (those with missing cell arrays) and empty walls with no cells are not supported. For growth planning purposes, PTP walls with the PTP/CEM mechanism absent and the porthole covered can be used until the PTP/CEM and adjacent LSM are

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installed. These virtual PTP walls are configured as standard walls until a PTP/ CEM mechanism is installed. The maximum number of cells per LSM depends on the wall configuration.

LSM Access Door


The LSM can be entered for operator procedures (typically recovery) or for service procedures. The door is locked and requires a key to be opened. Power is removed from the LSM robotics if the door is opened to assure the safety of personnel. Even when LSM power is off, the mechanical door has been opened (HBO) mechanism registers any door opening. When LSM power is restored, the LSM logs that the door was opened. Because cartridges may have been moved inside the LSM or removed from it, an HSC audit to catalog the LSM is required to ensure proper correspondence of the HSC dataset with the actual LSM contents. There are two types of doors available for the LSM. The standard access door has a 21-cell CAP and storage cells for storing up to 240 customer cartridges. The optional access door contains two large CAPs holding up to 40 cartridges each and a single cartridge priority CAP (PCAP). Customer storage cells are not located on the optional access door.

Cartridge Access Port (21-Cell)


The standard access door cartridge access port (CAP) provides for manual (operator) loading of cartridges into the LSM. It consists of a locked cabinet of 21 storage cells mounted in the LSM standard access door. The ACS controls the CAP door lock to maintain safe operations and to manage possible contention between CAP cell accesses by the operator and the robot. Access rules are observed by HSC and applied by the LMU to reserve the CAP to a single hosts operations at a time. Management of the CAP is shared among components of the ACS. Operator and application commands at the host inform the LSM (through the LMU) of the need to enter or eject cartridges from the LSM. When the door is unlocked, the operator can manually insert cartridges into or remove them from the CAP cells. When the door is closed, it is automatically locked by the LSM so the robot can safely access the cells. When the CAP is open, the robot can still operate (except moving cartridges to or from the CAP), since CAP door safety mechanisms protect the operator from coming into conflict with the robot.

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Cartridge Access Port (80-Cell)/PCAP


The optional access door contains two large CAPs. They are logically equivalent to the standard 21-cell CAP. They are independently controlled, with each of them capable of being in enter, eject, or idle mode without regard to the state of the other. The CAPs may also be operated in tandem, providing a single CAP with a capacity of 80 cells. These large CAPs are capable of holding up to four magazines of 10 cells each. When the CAP is opened, magazines may be removed from or inserted into the CAP or the cartridges may be loaded or removed individually at the magazine. Each CAP is locked by solenoid action when the door is closed. Sensors and switches detect CAP Locked, CAP Open, and each of the four magazines when they are present in the CAP. The priority CAP (PCAP) provides the ability to enter or eject a single cartridge that has been assigned a high priority. The PCAP operates independently of the two CAPs. The PCAP is automatically locked by a solenoid when the door is closed. Sensors and switches detect CAP Locked, CAP Open, and Cartridge Present. An operator's display panel is located above the PCAP on the optional door. It provides information about the status of each CAP and PCAP, error messages, magazines present, the number of cartridges in the CAPs, the VOLSER of the cartridge in the PCAP, and the cartridge present status of the PCAP. Figure A-20 on page A-65 is a block diagram of the 80-cell CAP door system interface. The cabling and connectors for the 80-cell CAP system are shown in Figure A-21 on page A-66 and Figure A-22 on page A-67. A brief description of the logic cards associated with the 80-cell CAP door is provided in the following sections.

80-Cell CAP Interface Board (MZ Card)


This board is the main interface to the LCU. It provides processor access (the LZ card in LCU) to all 80-cell CAP access door functions. All control, status, and power to the 80-cell CAPs is provided as input to the MZ card. This board resides on the right-hand side of the optional access door above the operator display panel.

80-Cell CAP Solenoid Driver Board (MW Card)


This board provides solenoid control and status for CAP door lock/unlock functions. There is one board for CAP 0 and one for CAP 1. They are located at the top of the access door, with MW0 on the left (as facing the door inside) and MW1 on the right. The PCAP lock/unlock solenoid control and status is not provided by the MW card, but it is provided instead from the LW card in the LCU.

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80-cell CAP Sensors (ME Cards)


There are 12 ME cards located on the optional 80-cell CAP access door. Signals generated from the LED sensors are outputted to the MZ card. Four cards mounted on the side of each of the two CAPs are used as Magazine Present Sensors 03. There is one card below each of the CAPs to sense CAP Open/ Close, one below the PCAP to sense PCAP Open/Close, and one located below the PCAP tray to detect Cartridge Present. Figure A-20. 80-Cell CAP Access Door Interface

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Figure A-21. 80-Cell CAP Cabling/Connectors (Sheet 1 of 2)

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Figure A-22. 80-Cell CAP Cabling/Connectors (Sheet 2 of 2)

Pass-Thru Port/Cartridge Exchange Mechanism


The pass-thru port (PTP) and cartridge exchange mechanisms provide the means for transferring cartridges among attached LSMs. Either the PTP or CEM is a mechanism shared by two LSMs that contains one (9320) or four (4420/ L5520) storage cells. A source LSMs robot can deliver the cartridges to the PTP/CEM. In the 4420/ L5520 PTP, the cells are rotated, making the cartridges available to the receiving LSMs robot. The receiving robot can extract the cartridges from the PTP and deliver them to designated cells, transports, or to another PTP.

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In the 9320 gravity CEM, the cartridge drops and is transported to the receiving robot, extracted from the Get cell, and delivered to designated cells, transports, or to another CEM. Management and control of the PTP/CEM is accomplished entirely within the ACS by the LMU. An LSM is master to a PTP/CEM it controls and slave to a PTP/ CEM controlled by a neighboring LSM. Each LSM can have up to four PTP/ CEMs, master to at most two. Common terminology is that the PTP/CEM mastered by an LSM is a master PTP/ CEM; a PTP/CEM which is acts as a slave to an LSM is a slave PTP/CEM.

Theta Arm Assembly


The arm assembly supports the Z mechanism, turntable, and hand assemblies between the inner and outer walls. The arm is supported at the center of rotation on a stationary column and projects through an opening between the upper and inner walls. The theta mechanism rotates about the center of the LSM to position the hands to a column of cells. If power fails, it comes to a stop that will not damage any part of the arm assembly. When power is off, it allows manual movement of the arm assembly. The Z mechanism provides vertical movement of the turntable and hand assemblies to locate a cell row. The 4410 contains a single Z column, whereas the 9310/L5510 has one at each end of the theta arm.

Turntable Assembly
The 4410 turntable assembly provides a turntable mounting for the two hand assemblies. The hand assemblies are opposed and fixed to each other: one always faces the inner wall, and the other, the outer wall. The turntable can rotate the hand assemblies, reversing the hands to face the opposite walls. The 9310/L5510 has a Z column attached to each end of the theta arm. Each Z column supports a turntable with one attached hand that can access either inner or outer walls.

Hand Assembly
The hand and finger assemblies extract or insert a cartridge in the designated cell or transport. Each hand assembly can rotate or extend independently. Rotation, with a roll mechanism, positions the hand to hold a cartridge vertically for placement into a cell, or horizontally for placement into a transport or a cell in the optional door CAP or PCAP. Extension, with a reach mechanism, positions the fingers into a cell or transport to grasp or release a cartridge. The 4410 and 9310/L5510 hands reach out and actually touch to sense the presence of a cartridge in a cell.

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Finger Assembly
The fingers of the 4410, with a touch sensor, determine if a cartridge is present in a cell or transport, and grasp the cartridge and hold it until movement to the desired location is completed. The 9310/L5510 fingers use spring tension to hold the cartridge in place while it is being moved. In either case, the fingers cannot release a held cartridge if there is a power failure.

Camera System
The camera system ensures accurate positioning of the hand to a cell or transport location and reads the OCR labels on the cartridges and calibration cells. Cells and transports contain a visually recognizable target. The camera system provides a target image to the LCU, which is interpreted to provide fine position commands. The camera reads the cartridge OCR label to assure proper cartridge selection and assists HSC in maintaining accurate records of cartridge locations (through the HSC audit function). A camera assembly is mounted on each of the hand assemblies.

Calibration
Calibration involves alignment and testing of the following elements of the LSM: Camera test Turntable alignment Z alignment Theta alignment

A calibration unit on the theta arm calibrates the turntable, roll, reach, and camera/finger alignment. The CAP, each wall, PTP/CEM, and drive location are calibrated, providing location calibration (per wall, using the wall ID cells) of theta, Z, and reach. A reserved area (not addressable by HSC) of special cells is used for storing diagnostic cartridges and cartridges found in-transit (in-hand) on power-on and before initialization is completed.

Remote Electronics Interface (4410)


The remote electronics interface (REI) card cage mounts to the theta arm and contains the servo electronics cards for controlling the movement of the Z, reach, finger, turntable, and roll mechanisms and camera lamps. The REI regulator (LS card), providing voltage and protection circuitry for the remote electronics, is also located in the REI card cage. Figure A-23 on page A-70 is a block diagram of the remote electronics.

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Figure A-23. Remote Electronics Block Diagram (4410)

The REI resides on the same card (LU) as the turntable servo. The REI supports the interface between the library control unit (LCU) and the LSM robot electronics and servo amplifier circuits. The REI controls command data transmissions intended for the robot electronics, except theta. As a single point interface, the REI decodes all

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addresses intended for a particular servo card, selects that card, and allows the devices on the card to receive or send data. Data transmissions are checked at each interchange so that data integrity is maintained. If a data error does occur, error information is stored, the LCU is alerted, and the robot mechanisms are brought to a safe stop. The REI is electrically connected to the LCU through differential drivers and receivers. The REI is composed of an 8-bit multiplexed address and data path and various control signals. All servo power amplifier circuits (except theta) and interface electronics are housed in the REI card cage.

Turntable Servo (4410 LU Card)


The turntable servo resides on the same card (LU) as the REI. Its hardware includes: Power drive circuitry for the turntable motor D/A converter for generation of current command Encoder decode and counter logic for generation of positional information Diagnostic circuitry FRU isolation circuitry

This circuitry is controlled by the REI electronics through an 8-bit data bus. Figure A-24 on page A-72 is a block diagram of the LU card. The REI portion of the card (Figure A-25 on page A-73) provides all address selections plus the read and write strobes to the LU turntable servo. All communication between the LU turntable servo electronics and the REI is through the REI data bus on the LU card.

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Figure A-24. Turntable Servo (LU Card) Block Diagram

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Figure A-25. Remote Electronics Interface

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Reach and Finger Servo (4410 LN Card)


The reach servo and the finger servo electronics reside on the LN card. The LN reach DC servo card hardware includes: Power amplifier circuitry for the reach motor D/A converter for generation of current command Encoder decode and counter logic for generation of positional information Diagnostic circuitry FRU isolation circuitry

This circuitry is controlled by the REI electronics through an 8-bit data bus. Figure A-26 on page A-75 is a block diagram of the LN card. The Finger Servo uses a two-phase stepper motor with a pulse-width modulation current control amplifier. Power to the amplifier is furnished by a 20 V linear regulator, which has an input of +35 V. All digital electronics which interface with the amplifier are driven from a separate regulated +5 V supply that is driven by the +20 V supply on the LN card. The servo is an open-loop system without feedback, except for open and close sensors. The REI (LU card) provides all address selects plus the read and write strobes to the LN reach and finger servos. All communication between the LN servo electronics and the REI is through a bus transceiver with parity.

Roll Servo/Camera Lamp (4410 LO Card)


The roll servo and the camera lamp circuitry reside on the LO card. The roll servo card hardware includes: Power amplifier circuitry for the Roll motor D/A converter for generation of current command Encoder decode and counter logic for generation of positional information Diagnostic and FRU isolation circuitry

This circuitry is controlled by the REI electronics through an 8-bit data bus. Figure A-27 on page A-76 is a block diagram of the LO card. The REI (LU card) provides all address selects plus the read and write strobes to the LO Roll servo. All communication between the LO roll servo electronics and the REI is through bus transceivers with parity. The camera lamp circuitry resides on the LO cards. Each LSM uses two LO cards, one for each hand. Each LO card controls two camera lamps, one on each side of the camera. Two quartz halogen flood lamps illuminate the cartridge area. Each lamp is operated at one-half of its rated voltage because of the sensitivity of the cameras and to extend the life of the lamp. The Camera Lamps diagnostic function monitors the filament voltage to the lamps to determine if a lamp needs service.

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Figure A-26. Reach and Finger (LN Card) Servo

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Figure A-27. Roll Servo/Camera Lamp (LO Card) Block Diagram

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Z Servo (4410 LV Card)


The LV card hardware includes: Power amplifier circuitry for the Z motor D/A converter for generation of current command Encoder decode and counter logic for generation of positional information Diagnostic and FRU isolation circuitry

This circuitry is controlled by the REI electronics through an 8-bit data bus. The REI (LU card) provides all address selects plus the read and write strobes to the LV Z servo. All communications between the LV Z servo electronics and the REI is through the bus transceivers with parity. Figure A-28 on page A-78 is a block diagram of the LV card.

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Figure A-28. Z Servo Block Diagram

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Remote Electronics Regulator (4410 LS Card)


The remote electronics regulator card is a DC-to-DC switching power converter, using a flyback circuit. It receives +35 V from the DC box in the LCU and converts it to a main output of +5 V and auxiliary outputs of +12 and -12 V. Two +24 V fan outputs are produced by linear regulators independent of the DC-to-DC converter. All inputs and outputs are safety extra low voltage (SELV) circuits. The LS card outputs share a common connection (low power ground) with the input. Protection circuits are provided for overload, low input voltage, high temperature, and output overvoltage and undervoltage. Indicator lamps are included for input and output presence and for the cause of regulator shutdown. A non-volatile memory stores card part number and related tracking information. Figure A-29 on page A-80 is a block diagram of the LS card power circuits. Figure A-30 on page A-81 is a block diagram of the LS card self-check circuits.

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Figure A-29. RE Regulator (4410 LS Card)Power Circuits Block Diagram

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Figure A-30. RE Regulator (4410 LS Card)Self-Check Block Diagram

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4480 Cartridge Subsystem

4480 Cartridge Subsystem


The 4480 Library Cartridge Subsystem consists of the Model M20 Control Units and Model M22 and/or Model M24 Cartridge Drive Units with Feature 4412 for attachment to the LSM. The control unit (CU) serves as the controller for up to eight transports. It interprets and distributes host channel commands to the appropriate transport and reports CU and transport status. It provides data buffering and data formatting, including error detection and correction. A CU provides one data path, connecting one of four channels to one of eight attached transports. Two CUs may be configured to allow two concurrent data transfers between two of eight channels and two of 16 transports. Each CU is microprocessor-controlled and contains a data buffer to maximize transfer rates at the channel interface. The CU supports data streaming rates of 2 and 3 megabytes/second (MB/s) and an interlock rate of 1.5 MB/s. The CU is functionally equivalent to the IBM 3480 Model A22. Each cartridge drive (CD) unit contains two or four transports and the common AC and DC power and pneumatic supplies to the transports it houses. The transports are independent and may be operated concurrently. They perform automatic tape threading, tape positioning, read/write functions, and status reporting to the CU. Transports are capable of a 3 MB/s transfer rate. The CD conforms to all requirements for handling and accessing IBM 3480 cartridges. Library CDs are physically attached to the LSM for robot placement of cartridges into the transports. There is a communications interface to the transports, giving the LSM control over what are normally manual operations (for example, load, unload); otherwise, the manual (non-library) and library units are identical. For more detailed information on the 4480 Cartridge Subsystem, the TimberLine Cartridge Subsystem, and the SD-3 Cartridge Subsystem, refer to the appropriate maintenance manual for that subsystem.

Transport Commands
The transport supports commands that may be invoked by the LSM. All command acknowledgments occur immediately.

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Rewind/Unload

Rewinds (if required) and unload the cartridge. The command is initiated in the transport and the acknowledgment made immediately. Status checks are required to determine when the unload is complete. Rewind nominally requires up to 60 seconds, depending on tape position in the cartridge. It may require up to seven minutes in certain transport recovery states. Unload requires about 10 seconds, half of which is elevator movement.

Reset Transport

Clears a check condition (if any), clear hold off load, and enable the operator panel display located in the LSM. Disables automatic elevator motion and cartridge loading when a cartridge is inserted into the transport. Allows elevator motion and cartridge loading if a cartridge is in the transport. Load requires about eight seconds, half of which is elevator movement. Disables the operator panel display (for normal LSM operation). The display is enabled on transport reset or by pressing rewind for two seconds when ready. For manual operation of the transport from within the LSM, the operator must set the READY switch to Not Ready after the display has been unblanked.

Hold Off Load Reset Hold Off Load

Blank display

Diagnostic Echo Sense

Returns the message as received. Returns requested status information.

LCU-Transport Interactions
To prevent the transport from moving the elevator when a cartridge is inserted, the LCU sends the Hold Off Load command to the transport before inserting the cartridge. When the cartridge is released and the fingers withdrawn, it issues the Reset Hold Off Load command and the transport then loads the cartridge. For unload, the LCU checks if a rewind or unload is required before issuing the command. Once issued, the LCU waits in a delay loop until the unload is completed, the transport reports an error, or communications is rejected. Each delay is based on the transports reported time to completion. While a transport has a loaded cleaning cartridge, the transport shows a Not Ready condition.

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Manual Operation
If the LSM is not operational, the operator gains access to the LSM by opening the access door and manually loads/unloads the transports that are connected to the LSM. The operator will be notified at the console, by the host computer software, when a mount/dismount is to be performed. When the operator initially enters the LSM to perform a manual operation, the transport panel displays will blank and a Hold Off Load condition preventing cartridge loads might be active for the transports. These conditions might still exist from a previous LCU command to the transports and must be cleared before manual operation. CAUTION: Tape damage: Never attempt to insert a cartridge into an LSM-attached transport until the operator panel display shows either StorageTek or the VOLSER/cartridge location information. The transport performs elevator motions during wake-ups when there is no cartridge present. Stay clear of the cartridge insertion opening during this time. When the wake-up has completed, the StorageTek display appears if the display is not blank.

Manual Operation Setup


To reactivate the transport display and clear the potential Hold Off Load condition, the drive must be unloaded. If the transport is loaded, go to the following paragraph for an explanation of unloading a transport. If the transport is unloaded and the READY switch is in the Ready position, holding the REWIND switch down for approximately 2 seconds unblanks the display and the pertinent information is visually displayed. The Hold Off Load condition is reset. If the operator continues to hold the REWIND switch down, the display brightness decreases to the next lower intensity step every 2 seconds (100%, 50%, 25%, and off). Holding the REWIND switch down results in the continued cycling of the display intensity. The brightness will remain at the level existing when the REWIND switch is released.

Manual Unload Operation


If the LSM is not operational and a cartridge is loaded on one of the transports, the host software notifies the operator on the operators console, when a dismount is to be performed. Normally the Unload command to the transport originates from the host software through the LMU/LCU. The operator, after gaining entry into the LSM, locates the transport and unloads the cartridge by placing the Ready switch in the Not Ready position (press the

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4480 Cartridge Subsystem READY switch), and momentarily pressing the UNLOAD switch. The transport

unloads the cartridge and the cartridge can then be removed from the transport through the opening in the air box cover of the CD wall. A transport in a library configuration has the cartridge eject mechanism physically disabled. When the transport is unloading the cartridge, the tape is not ejected out of the elevator like standalone transports. To enable the display for the transport after it is unloaded, see the previous paragraph. The operator panel display, when unblanked after the unload is completed, will display STORAGETEK.

Manual Load Operation


The operator is notified at the operator console of a load operation for a transport attached to a non-operational LSM. After entry to the LSM has been achieved, the operator should first unblank the operator panel display and reset the Hold Off Load condition. This procedure is described in Manual Operation Setup on page A-84. If the operator continues to hold the REWIND switch down, the display brightness decreases to the next lower intensity step every 2 seconds (100%, 50%, 25%, and off). Holding the REWIND switch down results in the continued cycling of the display intensity. The brightness remains at the level existing when the REWIND switch is released. After this has been accomplished, the display for that transport alternately shows the VOLSER number and the location of the cartridge inside the LSM. The location is displayed by wall number, column, and row of the cartridge and originates from the host software Load Display command. After the operator has located and verified the cartridge VOLSER, the cartridge is placed into the transport carriage. The transport loads the cartridge when the cartridge-present sensor is activated (the cartridge is fully inserted). On the transport attached to an LSM, there is no door to close to initiate the cartridge loading.

Return to Library Use


When the LSM is ready to be returned to the customer, the transport Ready Switch must be in the Ready position before closing the LSM access door. See Library Storage Module Restoral in Chapter 7, Equipment Restoral Procedures.

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4430 LMU Terminal Control Unit Interface

This appendix provides an overview of the 4430 Library Management Unit (LMU) to terminal control unit (TrCU) Interface. Special requirements for the IBM and McDATA terminal control units are described as applicable.

Host Interface Definition


The Nearline automated cartridge system connects to up to 16 host central processing units (CPUs) through the LMU/TrCU interface. This is done by the LC card (interface processor module or IPM) in the LMU emulating a subset of the 3278 Model 2 Terminal Display Station. Up to 16 IPMs can be installed in an LMU. Each IPM is connected through coaxial cable to a 3274 (with Category A adapter) or 3174 type terminal control unit port. Each terminal control unit is connected over a local, non-systems network architecture (non-SNA) channel interface to a single host CPU. Every host CPU using the library must be connected to different TrCUs that are all connected to individual IPM cards in the LMU. The IPM cards support a subset of the 3278 Display Station to 3X74 protocol. For this reason, it is not always true that any terminal control unit that can interface with a 3278 can, without modification, also interface with an LMU. In some cases, the terminal control unit must be configured differently to communicate with the IPM in the LMU as described in this appendix.

Approved Terminal Control Units


To attach to the host software component (HSC) running in a host CPU, the terminal unit must be attached as a local, non-SNA type control unit. The terminal control unit can attach to the LMU only through Category A device adapter ports. This limits the acceptable terminal control unit types to those listed below. Unique requirements are described later in this appendix. IBM 3274 Models 1D, 21D, 31D, and 41D IBM 3174 Model 1L, 11L, and 21L IBM 9034 ESCON Converter (used with the 3174)

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Cable Type/Lengths

IBM 6020, 6120 Workstation Controller (for 9373/9375 VM Server) McDATA MC74 Model 41A (emulates IBM 3274 xxD) and McDATA OEM customer boxes: Harris Corporation, H274-41A Memorex, 2274-2A Beehive/MDS/Momentum, 9274-4A Alcatel (ITT)/Courier, 947401L

McDATA MC400 Model 1L (emulates IBM 3174 1L) and McDATA OEM customer boxes: Harris Corporation, H17432L Memorex, 137401L Beehive/MDS/Momentum, N/A Alcatel (ITT)/Courier, N/A

Note: StorageTek has dropped all 3274 B Terminal Control Unit models from the approved TrCU list; the 4400 Automated Cartridge System does not support them.

Cable Type/Lengths
For coaxial cable, use RG-62AU (93 ). For twisted-pair telephone wire, use IBM Cabling System Type 3 media or equivalent. The maximum allowable lengths of the coaxial cable/wire from the terminal control unit to the LMU is half of that specified by IBM. This is because there is a diagnostic function in the LMU called 3270 wrap, where one IPM is cabled to another (in the same LMU) and message traffic is sent between the two to verify functionality of the IPMs and of the attaching cable. The test is intended to run using the existing coaxial cable that runs from the terminal control unit to the LMU, providing that both IPMs are connected to the same control unit or two control units in close proximity. If the 3270 wrap is run using the existing cable, then both cables together cannot exceed the IBM specified lengtheach cable can only be a maximum of half the IBM specified length. If a short jumper coaxial cable at the LMU is used instead of the existing cables while running the 3270 wrap, the normal IBM specified cable lengths apply and the terminal control units can be allocated farther from the LMU. Table B-1 on page B-3 defines the maximum allowable cable lengths as specified by StorageTek (half the IBM lengths as described previously) and by IBM.

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Table B-1. Maximum Cable Lengths Maximum Lengths in Meters (Feet) Cable Type RG-62A/U Twisted (see Note 1) Cable Type RG-62A/U Twisted (see Note 1) Notes: 1. The twisted pair wire has a minimum length requirement of 31 m (100 ft). 2. The 3299 Multiplexer doubles the cable length from the terminal control unit to the LMU because the 3299 can be located up to 1500 m (4920 ft) from the terminal control unit and the LMU. Without 3299 Terminal Multiplexer 750 m (2460 ft) 137 m (450 ft) 1500 m (4920 ft.) 274 m (900 ft.) 1500 m (4920 ft) 274 m (900 ft) 2999 m (9840 ft) 549 m (1800 ft)

With 3299 (see Note 2). Terminal Multiplexer

3299 Usage Requirements


The IBM 3299 Terminal Multiplexer converts one coaxial port on the terminal control unit side to eight ports on the device (LMU) side. It also allows the distance between the terminal control unit and the LMU to double because the 3299 can be located up to 4920 feet (1500 m) from the 3299. The McDATA MC99 Device Multiplexer is compatible with the IBM 3299. Use of the 3299/MC99 is transparent to the LMU and approved with an LMU.

Foreign Language Operation


Foreign language options (as listed in the IBM manual, PN GA23-0061-2, Appendix D) for the TrCU do not adversely affect the interface to the LMU and are approved for use. However, Portuguese might not function due to its nonuse of the < character (EBCDIC 4C), which the host I/F uses to signify the beginning of a message. It is unclear whether 4C can be used regardless and engineering is unable to test this functionality in a reasonable fashion. Note that Japanese English and Japanese Katakana are approved for use.

IBM 3274 1D, 21D, 31D, and 41D


These terminal control units are connectable only as a local Non-SNA, channel-attach. No special configuration requirements are needed to allow operation with an LMU. Only Category A device adapter ports can be used with the LMU.

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IBM 3174 1L, 11L, 21L

Note: The 3274 21B is not approved for use with the LMU. There is no minimum code level. The only restriction is Port 00 on the device side of the terminal control unit cannot be connected to the LMU at the time of the terminal control unit initial program load. This is because IBM has assigned Port 00 special functionality during this time, and it is recommended that Port 00 not be connected to the LMU at all.

IBM 3174 1L, 11L, 21L


This terminal control unit is a superset of the 3274 local-attach family, servicing Category A type adapters only. The 3174 must be operated in the 3274 emulation mode (local, non-SNA, channel attach, 3270 device side interface). One specific change must be made to the default configuration file on the control diskette of the 3174 at initial program load in response to configuration Number 125: Bit 6 of the miscellaneous features options byte (file transfer aid bit) must be set. (This typically means loading a 04h into Word 125.)

This is required since the normal 3278 protocol involves multiple keystrokes that are read one at a time by the 3174. The LMU, however, operates in a mode where blocks of data are read by the terminal control unit in response to the ENTER switch from the LMU. Setting the file transfer aid bit causes the terminal control unit to read the entire screen upon receipt of an ENTER switch in addition to its normal keystrokeby-keystroke operation. Note that this causes all 3174 ports to operate in the file transfer aid mode. The overall throughput of the 3270 interface for all ports on this terminal control unit decreases somewhat because of the additional operation of reading the entire screen. This effect, however, should not be noticeable in most customer environments. There is no minimum code level. All code levels tested function properly with the LMU except as explained in the following note. Note: Upgrading the 3174-1L, 11L, and 21L to microcode Levels B2.0 or B3.0 has presented incompatibility problems with the LMU. IBM has corrected this problem by releasing PTR 9032 for B2.0 code and PTR 8615 for B3.0 code. These PTRs must be installed for proper TrCU to LMU communication. Microcode B4.0 incorporates these PTRs as part of its release. Some accounts have experienced problems when Configuration Entry 110 was loaded with a non-zero value. This entry is for multiple logical terminals using multi-host support and may require additional TrCU memory installation. All

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configuration entries should be understood and referenced to the appropriate IBM Controller Planning Guide, GA27-3862-02. The only restriction is Port 00 on the device side of the terminal control unit cannot be connected to the LMU at the time of the terminal control unit initial program load. This is because IBM has assigned Port 00 special functionality during this time, and it is recommended that Port 00 not be connected to the LMU at all. Note: The 3174 occasionally locks-out the LMU by indefinitely setting a keyboard lock condition. Although the situation is recoverable using LMU time-outs, errors (650D) are logged. Installation of LMU/library storage module (LSM) Firmware 2.3 or higher, with LMU (IPM PNs 410183210, 410183310) EC 28158 PROM change, should reduce or eliminate all 650D errors.

IBM 6020, 6120 (VM Server)


The IBM 6x20 Workstation Controllers used on IBM Enterprise System/9370 VM Storage Servers essentially emulate a 3174 type TrCU with Local attachment for Category A devices only. The 6x20 Workstation Controller has various configuration options, so take care to operate it only in the 3274 emulation mode (local, non-SNA, channel-attach, 3270 device side interface). The same cable restrictions apply to the 6x20 Workstation Controller as for the 3174 TrCU. The following attachments have been tested and qualified: 9375-060 with 6120 Workstation Controller 9375-060 with 6020 Workstation Controller 9373-025 with 6120 Workstation Controller

There is no minimum code level. The latest microcode level tested was IBM GA9 microcode. This microcode caused an interface lock-out condition to occur after a power-on-reset sequence was initiated by the workstation controller. A power-on reset normally occurs when a terminal device is powered off and then back on, or in the case of the LMU, when the IPM is reset. The following IBM Microcode patches correct the problem. P332691058 for Workstation Controller EC Level A83072 microcode P332691057 for Workstation Controller EC Level A83073 microcode

The only restriction is that the LMU cable (RG-62, 93 ) be connected to Port 2 on the 6x20 Workstation Controller. Installations are normally supplied with a 61-m (200-ft) cable.

IBM 9034 (ESCON Converter)


The IBM 9034 ES Connection (ESCON) Converter allows the attachment of ES Connection channels to parallel control units. Essentially, the 9034 converts from duplex fiber-optic cable connect to Bus and Tag cable connect (3174 TrCU

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McDATA MC74 41A, MC400 1L

Host Channel). A fiber-optic host channel can be connected directly to the 9034, or indirectly through a 9032 ESCON Director. The 9032/9034 devices are essentially transparent to the 3174/4430 LMU interface. IBM documentation indicates that the 9034 can be attached to 3174-x1L and 3274A, B, and D TrCU models. A duplex fiber-optic host channel attached to a 9032 ESCON Director attached to a 9034 ESCON Converter attached to a 3174-11L TrCU, which was attached to an ACS 4430 LMU/IPM has been tested. There are no special configuration requirements needed. Configuration requirements are based on the 3174 TrCU attachment to the LMU. There is no minimum code level. The location of the 9034 depends on a combination of factors, including the length of the Bus and Tag cables, the channel/control unit distance, and storage type. The distance between the 9034 and the control unit cannot exceed the maximum distance supported for the parallel (Bus and Tag) cable environment. The maximum distance from a channel to a 9034 is 3 km (1.9 miles). The maximum channel data rate with a 9034 channel connection is 4.5 MB per second and varies by control unit.

McDATA MC74 41A, MC400 1L


The MC74 41A Terminal Control Unit emulates IBM 3274, and the MC400 1L emulates IBM 3174, with local attach for Category A devices only. McDATA has indicated that there is no difference between the McDATA OEM boxes listed in the Approved Terminal Control Units on page B-1 and the McDATA boxes. McDATA OEM boxes are approved for use with the LMU. For the MC74 41A and MC400 1L, one specific change must be made to the default configuration file on the system disk. In the local control point (LCP) program under the Configure Options (CO) menu, the PC file mode transfer byte must be set to 01. This is required since the normal 3278 protocol involves multiple keystrokes that are read one at a time by the MC74 or MC400. The LMU, however, operates in a mode where blocks of data are to be read by the terminal control unit in response to an Enter key from the LMU. Setting the File Mode Transfer byte causes the terminal control unit to read the entire screen upon receipt of an ENTER switch, in addition to its normal keystroke-by keystroke operation. Note that unlike the IBM 3174, setting the file mode transfer byte only affects the port specified (attached to the LMU) and does not cause the overall throughput of the 3270 interface on the other ports of the terminal control unit to decrease. The MC74 uses McDATA code Level 3.4 or higher. The MC400 has no minimum code requirement and should function properly with the LMU except as explained in the following note.

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Note: Upgrading the McData/Memorex 1374-01L to microcode Levels 5.2 or 5.3 has presented subtle incompatibility problems with the LMU. FSCs 6504, 6510, 6538, 653F, 6550, and 65FF have been logged as a result of this incompatibility. Time-outs on tape mounts and loss of HSC activity reports resulting in SLS0681D, SLS0682D failure messages has also been observed. The failures occur at an average frequency of about one every three days. Consequent study of the problem has resulted in a microcode fix incorporated in code Level 5.3.0.24 Port 00 can be used by the LMU on McDATA terminal control units.

Related Documents
The following is a list of documents relating to the information described in this appendix: IBM 3274 Control Unit and Programmers Guide, GA23-0061-2. which describes IBM 3274 Control Unit host-side interface, local operations, non-SNA operations, 3274 error indications, control unit diagnostic procedures (Test mode), and the 3278 (terminal) operator information area. IBM 3174 Subsystem Control Unit Functional Description, GA23-0218-0, which describes the 3174 host-side interface, local operations, and non-SNA operations. IBM 3174/3274 Control Unit to Device Product Attachment Information (PAI), October 16, 1986 (not a numbered document), which describes 3174-to-LMU protocol (over the coaxial cable), device buffer coding (character set used 3274-to-LMU), and coaxial cable transmission timing and description. McDATA MC400 Model 1L/1R/2R/3R (3174 Compatible CU) Systems Manual (not a numbered document), which describes hardware, configuration changes (LCP), diagnostics, and the operator information area. McDATA MC74 MODEL 41A (3274 Compatible CU) Operations and Maintenance Manual (not a numbered document), which describes hardware, configuration changes (LCP), diagnostics, and the operator information area. IBM 3274 Control Unit Customizing Guide, GA27-2827-15, which describes the procedure to customize the configuration of the IBM 3274. IBM 3174 Subsystem Control Unit Customizing Guide, GA23-0214-2, which describes the procedure to customize the configuration of the IBM 3174. StorageTeks Automated Cartridge System Diagnostic System Users Guide, PN 88555, which describes diagnostic procedures and tools. IBM Enterprise System/9370 I/O Subsystems Service Guide, SY24-4054-05, which describes 9370 problem isolation techniques and error codes.

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IBM Enterprise System/9370 Work Station Subsystem Utilities Guide, GA24-4044-06, which describes the workstation customization guidelines. StorageTeks 4400 VM Storage Server Turnkey Installation Guide, PN 404406701, which provides the functional description of the VM server, plus attachment and customization information. IBM Introducing Enterprise Systems Connection, GA23-0383-0, which describes the 9034/9032 general attachment capabilities. IBM Planning for the 9034 Enterprise Systems Connection Converter, GA23-0362-0, which describes configuration planning and attachment capabilities. IBM Planning for Enterprise Systems Connection Links Converter, GA23-0367-1, which describes planning, installation, and specification information for ESCON links.

Interface Diagnostic/Troubleshooting Tools


There are various diagnostic and troubleshooting tools to use to isolate faults in the 3270 interface between the TrCU and the LMU. These include the state of the IPM (LC card) LEDs, the 3270 wrap test, the IPM-TrCU status check, the TrCU-based diagnostics, and channel status tracing. See Table 3-3 on page 3-18 and Figure 3-4 on page 3-21 for LC card edge LEDs and their definitions. The 3270 wrap test is an LMU diagnostic that verifies the functionality of the LC card 3270 interface hardware and firmware. Refer to the Automated Cartridge System Diagnostic Users Guide, PN 88555, for information on how to use this diagnostic test. The IPM-TrCU status check is an LMU diagnostic routine used to present the user with information contained in the operator information area (OIA) line on the virtual screen in the IPM. This information is displayed as the bottom line on 3278 type terminals. It is useful in isolating the cause and type of intermittent 32760 faults. Refer to the Automated Cartridge System Diagnostic Users Guide, PN 88555, for information on how to use this diagnostic test. Both IBM and McDATA have built in diagnostic and statusing functionality that is available to the user. Refer to the manufacturers documents listed in Related Documents on page B-7 for more information on the use of these functions. Channel traces taken during failed host-to-LMU communication attempts give valuable information in the form of the sense byte and status byte that the TrCU returns to the host. Refer to the appropriate IBM documentation for a breakdown of the bit interpretations of these bytes.

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Glossary
The following terms are used in this guide or apply to this product.

C
CAP See cartridge access port. cartridge The plastic housing around the tape. A plastic leader block is attached to the tape for automatic threading when loaded in a drive. The spine of the cartridge contains a VOLSER label listing the volume identification number. cartridge, 9840 The plastic housing around the tape. It is approximately 109 mm (4.3 in.) by 125 mm (5in.) by 25 mm (1 in.). The housing contains the tape and two reels for automatic threading when loaded into a drive. The spine of the cartridge contains a label listing the VOLSER (tape volume serial number). cartridge access port (CAP) An assembly that allows an operator to enter and eject up to 14 cartridges during automated operations. The operator can open the CAP and place each cartridge into the cells or place a preloaded array into the CAP. The CAP is located on the right front door of the library storage module. cartridge drive (CD) A 4480, 9490, or SD-3 device that houses either two or four cartridge tape read/write devices, which are referred to as transports. cartridge exchange mechanism (CEM) A mechanism that allows a cartridge to pass through from one library storage module (LSM) to another in a multiple LSM automated cartridge system. See also pass-thru port. cartridge tape The magnetic tape enclosed in a plastic housing. cartridge tape unit (CTU) A 9490 or SD-3 device that houses either two or four

Special Characters
micro or micron. 10-6.

Numerics
4890 A device that reads from or writes to a magnetic tape. 9840 A cartridge drive that reads from or writes to tapes. The housing for the tape contains supply and take-up reels.

A
AC Alternating current. ACS See automated cartridge system. A/D Analog to digital. audit For a host, its request to catalog the cartridges in an LSM (or ACS) by LSM number, panel, row, and column. automated cartridge system (ACS) The library subsystem consisting of one library management unit (LMU) and at least one library storage module (LSM) attached to that LMU. It was previously referred to as ACHS and ATHS. automated mode A relationship between an library storage module (LSM) and all attached hosts. In automated mode, the robot moves cartridges among the storage cells, cartridge access port (CAP), and drives. This is the normal operating mode of an LSM that is communicating with all host central processing units.

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Glossary

cartridge tape read/write controllers or devices. catalog The inventory of all cartridge storage locations in an library storage module (LSM); this inventory is by LSM number, panel, row, and column. CCW Channel command word or counterclockwise. CD See cartridge drive. CDI Camera direct memory access (DMA) interface. cell A slot in the library storage module that is used for storage of a cartridge tape. CEM See cartridge exchange mechanism. channel A device that connects the host and main storage with input/output control units. check (CHK) The detection of an error condition or test for correct condition. CHK See check. CIM See customer initiated maintenance. CNTL Control. CNTR Counter. configuration The description of a library storage module, listing the panel types and drives. CSS See Central Support Services. CTU See cartridge tape unit. CU Control unit (for 4480 Tape Subsystem). customer-initiated maintenance (CIM) The customer calls Central Support Services to report a problem. Central Support Services (CSS) The remote diagnostic center at StorageTek. Service personnel can access and test StorageTek equipment and software, through telecommunications lines, from certain

remote customer installations. It was previously referred to as the remote diagnostic center (RDC) and the Central Support Remote Center (CSRC). CW Clockwise or continuous wave.

D
D3 See Detached Diagnostic Device. D/A Digital to analog. DAC Digital-to-analog converter or dynamic amplitude control. data set A major unit of data storage and retrieval that consists of a collection of data (in a prescribed arrangement), which is described by control information to which the system has access. Data Management Software (DMS) The software package responsible for communications between the library storage module and an IBM host. DBR Dynamic brake relay. DDD See Detached Diagnostic Device. DDR See Dynamic Device Reconfiguration. demand allocation An MVS term; a user has requested a specific unit. Detached Diagnostic Device The StorageTek 392X unit that is an intelligent terminal used by solutions delivery engineers to communicate with or test StorageTek devices. DEV Device. device number A four-digit hexadecimal number that uniquely identifies a device attached to an XA processor. device separation The function of directing allocation to the library or not, depending on that allocation requiring a library or non-library transport or cartridge tape unit.

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diagnostic programs Tests, accessible through the library storage module (LSM) operator panel, that allow a local user to run offline tests within the LSM. directed allocation The function of directing the allocation of library transports or cartridge tape units (CTUs) so as to allocate a transport or CTU nearest the requested volumes cell. DMA Direct memory access. DMS See Data Management Software. DSP Dynamic Support Program. Dynamic Device Reconfiguration (DDR) The facility provided by MVS to allow a volume to be moved from one drive (or cartridge tape unit) to another while the volume is being used.

and the true, specified, or theoretically correct value or condition. error recovery procedures (ERPs) Procedures designed to help isolate and, where possible, to recover from errors in equipment. ESD Electrostatic discharge. ESP Early support program. ExtendedStore LSM A library storage module without a cartridge drive (CD) or cartridge tape unit (CTU) attached. The hinged CD wall has a decorative cover mounted instead of a CD or CTU. Four jumper plugs are connected to the CD interface connectors on the library control unit upper input/output panel.

F
fault symptom code (FSC) An error or information code generated by functional or diagnostic software that might directly or indirectly be used to indicate the field replaceable unit that is probably causing the error. FDR Fast dump, restore or field data report. Federal Information Processing Standard (FIPS) A data interface between the drives and a host. field replaceable unit (FRU) An assembly that is replaced in its entirety when any one of its components fails. FIFO First in-first out. FIPS See Federal Information Processing Standard. FRU See field replaceable unit. FSC See fault symptom code.

E
EC Engineering change. EEPROM See electrically erasable programmable read-only memory. electrically erasable programmable readonly memory (EEPROM) A non-volatile sequential access memory device that can be written into when a change of contents is required. EMI Electromagnetic interference. EPO Emergency power-off. EPROM Erasable programmable read-only memory. EREP Environmental recording, editing, and printing. ERPs See error recovery procedures. ERPA Error recovery procedure action code. error A discrepancy between a computed, observed, or measured value or condition

G
GB See gigabytes.

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Generalized Trace Facility (GTF) An MVS facility used to trace software functions and events. gigabytes One thousand million bytes (109 bytes). GTF See Generalized Trace Facility.

K
KB See kilobytes. Kb See kilobits. kilobytes (KB) One thousand bytes (103 bytes). kilobits (Kb) One thousand bits (103 bytes).

H
HDW Hardware. home location The cell in a library storage module in which a cartridge is stored. A cartridge returns to this location when it dismounts from a drive or cartridge tape unit.

L
LAD Lock access door. LCU See library control unit. library control unit (LCU) The portion of the library storage module that controls the choosing, mounting, dismounting, and replacing of cartridges. LED Light emitting diode. library A library is composed of one or more automated cartridge systems (ACSs), attached cartridge drives or cartridge tape units, volumes placed into the ACSs, host software that controls and manages the ACSs and associated volumes, and the library control datasets that describe the state of the ACSs. library management unit (LMU) The portion of the automated cartridge system that controls the library storage module and communicates with host central processing unit. library storage module (LSM) A unit that contains the storage area for cartridges, the robot that moves the cartridges and the drives or cartridge tape units. LIBGEN The process of defining the configuration of the library to the host software. LIFO Last in-first out. logical ejection The process of removing a volume from the control datasets without physically ejecting it from its library storage

I
ID Identifier or identification. inlines Inline diagnostics (those interleaved with a host request to an online library storage module). initial program load (IPL) A process that activates a machine reset and loads system programs to prepare a computer system for operation. Processors with diagnostic routines activate these routines at IPL execution. installation verification package (IVP) A package of programs that a user can run after the library has been installed to verify that the library is functioning properly. intervention required Manual action is required. in-transit cartridges Cartridges left in the robot hand. The Data Management Software must recover these cartridges to a known location to clear out the software in-transit record. IPL See initial program load. I/O Input/output. IVP See installation verification package.

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module (LSM). This is a consequence of the LSM or automated cartridge system being in manual mode. LMU See library management unit. LSM See library storage module.

MJB Modem junction box. MNT-I See maintenance interface. modem Modulator/demodulator. monitor A device that observes and verifies the operations of a system to indicate any significant departure from the norm. MP Maintenance panel. MPLX Multiplex. ms Milliseconds, or 10-3 seconds. MTBF Mean time between failures. MTTR Mean time to repair. MUX Multiplex. MVI Maskable vectored interrupt. MVS Multiple virtual storage. mws See milliwatts.

M
maintenance interface (MNT-I) An RS-232C interface from the unit under test to a modem, modem junction box, or Detached Diagnostic Device. maintenance facility (MF) A component of the control unit (CU) or library management unit (LMU) providing the logic necessary for local and remote diagnostic interface and communication with the CU or LMU operator panel. manual mode A relationship between an library storage module (LSM) and all attached hosts. An LSM operating in manual mode is not communicating with all host central processing units and requires human assistance to perform cartridge operations. MB See megabytes. Mb See megabits. megabytes (MB) One million bytes (106 bytes). megabits (Mb) One million bits (106 bytes). MF See maintenance facility. MFCS Manufacturing first customer ship. MFG Manufacturing. miliwatts (mws) 10-3 watts. mixed configurations Those customer accounts that contain drives or cartridge tape units (CTUs) within the library as well as drives or CTUs outside of library control and that cause the host software to alter allocation to one or the other.

N
NMI Non-maskable interrupt. NVI Non-vectored interrupt. NVRAM Non-volatile random access memory.

O
OCR Optical character recognition. OCR label See optical character recognition label. OLT Online test. OP Operation, operational, or operator. online A state of being controlled directly by or in direct communication with a computer. Available for functional use. op