IOU_54_Field_Maint IOU 54 Field Maint

IOU_54_Field_Maint IOU_54_Field_Maint

User Manual: IOU_54_Field_Maint

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100 54
DISC DRIVE

MAINrENANCE FIELD MANUAL

PRELIMINARY EDITICN

This document contains proprietary information of
fwbhawk Data Sciences Corp. (MDS) and shall not be
disclosed to any third party, or used for any purpose
other than that for which it was supplied, or reproduced
without the prior written consent of MOS.

11/03/83 PAGE

1

1.1 GENERAL
The IOO 54 controller is a disk controller that is used with the 10 .. 5"
Fujitsu Eagle (470 MB).
The IOO 32/42/52 controllers ensure data integrity by verifying each sector
imnediately after each write operation. The IOO 54 controller offers an
alternative approach: each sector may be written without verification with the
expectation that infrequent read/write errors will be recnvered when the sector
is read using the error correction process. This option has not yet been
implemented, however it may be available in the near future.
the error correction process is capable of recovering a small error (a single
"burst-' of up to 11 consecutive bits), and rot a large error, all sectors with
media defects must be alternated prior to using the disk. If this procedure is
rot followed data will be lost inmediately on uncorrectable sectors and sanewhat
later on sectors that become uncorrectable through time. The disk must also be
periodically analyzed in order to detect and alternate marginal sectors.
As

There will be a magnetic tape with each Fujitsu Eagle Disk that will have a
canplete list of defects on that particular unit. '!he ATP MISC54 will have a
formatter that will read in the tape, and will automatically generate an
al ternate sector for each defective sector.

1.2 SPOCIFICATIrns
PcMer Requirerrents:

+5 VOC
+12 VOC
-12 VOC

4.9 Amps,
200 rnAmps
200 rnAmps

Max.,

Noise/Ripple - 50nw pp.

Regulation:
Only the +5 VOC pc7Wer must be regulated; voltage tolerance is specified at
+10%.

11/03/83 PAGE

2

INSTALIATICN
2.1 SWITCH SEI'I'!NG3

The controller is usually set to address "D", but can be set to any address that
is not being used by another device.
The setting of the configuration switches depends upon the disk drive being used
at"1d whether the verirj-after-write check is enabled. Use the following table to
set the configuration switches:
Fujitsu 10.5" Eagle 470 MB

$96 or $16

The $80 switch is set to "I" if the verify-after-write check is enabled ..
1HPORrANl' - Until further notice, all 1aJ 54 1 s will be configured for verifyafter-write (ie. 96).

2.2 CABLING
The 100 54 is connected to the disk drive by two ribbon cables. The radial
cable, which is connected to P3 on the 1aJ 54 has 26 conductors. The buss
cable, which is connected to P4 on the 100 54 has 60 conductors.
The red stripe must face up whenever a cable is connected to the 100 54. The
red stripe must also correspond to pin 1 on the disk drives' interface connector
(pin 1 is often marked by an arrowhead on the interface connector I or a pin
nunber near the connector).

" . 11/03/83 PAGE

2.3 WRITE CXNrroL mS'I'RICl'ICNS

Device controls are issued to the IOU 54 in the follCMing format:
Idyy9D

(d

= controller address

OJDE

&

yy

= control

byte)

DEFINITICN

$01
$02
$03
$04
$05
$08
$09
$10
$14
$20
$21
$30
$31
$41
$42

AllaN access to FE and reserved sectors
Bypass verify-after-write check (next write only)
Start mem::>ry I/O rrode .
Reset rnerlDry I/O nxXle
Start user mode (Jump to location $8000)
Seek using a physical sector address
Verify instead of write
Disable completion interrupts
Enable completion interrupts
Reset error counters
Read error counters
Disable read retries
Enable read retr ies
Clear tick on each read/write sector operation
Set tick on each write sector o:peration and enter disk

$44
$60
$70
$71
$72
$73
$75
$76
$7F
$99

Start tick-scan IOOde
Disable alternate sectoring
Enable alternate sectoring
Alternate next: sector
Start read map rrode
Reset read map mcde
Start format disk node
Start diagnostic mcde
Read identification string
Read next sequential logical sector
Initiate automatic read of next sector
Disable verify-after-write check
Enable verify-after~ite check
M::>ve R:M. version
to status byte 0
Read controller parameters
St~t set drive characteristics mode
Read status buffer
Read trace buffer
Set status byte 0 to $04
Set logical sector address extension

I/O IOCrle

$9A

$9B
$9C
$AO
$Al
$A2
$A3
$A4

$BO
$xD

*'

3

11/03/83 PAGE

4

2.4 TRACE CXDFS
The trace buffer contains information about the last disk operation and is of
the following form:
byte 0
bytes 1-150

Number of subsequent bytes that contain trace buffer entries
Trace buffer entries

Each trace buffer entry consists of a I-byte trace code and a 3-byte binary
sector address, or a 3-byte drive status in the case of trace code $60. If the
high order bit of the trace code is set (e.g. $81 instead of $01), the sector
address refered to by the trace code is the same as for the previous trace
buffer entry. For decoding purposes, the $80 bit must be subtracted from each
code.

TRACE
a:>DE

$01
$02
$04
$05
$06
$07
$08
$09
$OA
SOC

SOD
$OE
$11
$12
$l3
$14
$16
$17
$18
$19
$1A
$1B
<:: 1,.,

v ...'"

"$lE
$lF

$20
$21
$22
$23
$24
$25

DEFINITICN

On-cylinder status immediately after seek initiation
Fault, seek error, or power fail status immediately after
seek initiation
Timeout waiting for on-cylinder
Fault, seek error, or power fail status after on-cylinder
status
Fault after sequence comnand
CRC error after nnormal n read
Header EOC error
Tinout waiting for disk state machine
User requested invalid sector address
Data does not compare on verify
Unable to assign new alternate
Valid header after "iooexedn read, but wrong cylinder
I.SA not in alternate sector map
Fault after head select
Unable to read alternate map
Error using alternate sector
Cannot match header
Valid header after nindexed" read, but wrong head
(Reserved)
Fault or power fail condition
Unable to clear fault
Dr i ve not ready
Ur~le to restore drive
Invalid request
Error in microcode
Invalid interlace parameter
Insufficient RAM for drive tables
Unable to write sequence tables
Spurious entry into format logic
Write instruction expected from user
Unable to read any header on requested track

11/03/83 PAGE

- TRACE
CDJE

5

DEFINITlOO

$27
$28
$29

TWo consecutive control errors
Unable be write reserved secbers
Controller is inoperative
Retry er ror, "out" read
Retry error, "in" read
Retry error, "normal" read
Retry error, "ear ly-normal" read
Retry error, "early-in" read
Retry error, "early-out" read
Retry error, "late-in" read
Retry error, "late-out" read
Retry error, "late-normal" read
Retry operation
Read from index
Alternate map search
Assigning new alternate
Rewr i ting header and data
Seeber is marked
Retry after header match, but compare error
Attempting BEP error correction
BEP reports error is uncorrectable
Clearing tick
Verifying head position
Drive status (oonsists of unit status, read/write check
status and access status bytes; if the drive does not
support extended status, the last b.o bytes will be zero).
Trace buffer full

$30
$31

$32
$33

$34
$35

$36
$37

$38
$41
$42
$43

$44
$47
$48
$49
$4A
$4B

$50

$51
$60
$FF

2.4.1 STATUS IN
The format for Status In (Read Status 0) is:
4dyy9D

(d = controller address

& yy =

test byte)

STATUS

STATUS

BYTE

ODE

$01
$02

Read busy
Write busy

$04
$08
$10

Service Request
Flag 1, seek or write completed (successfully)

End

.

The following completion codes are designated by the three highest status bits
as shown below:
000

Successful completion

11/03/83 PAGE

Unrecoverable error (read, write or verify)
sector
Invalid sector number
Write attempt while drive is write-protected or not ready
Alternated sector not found in the map
Drive not formatted
Ser ious dr i ve problem: invalid request of hardware problem,
see trace and status buffers

001
010
011
100

Mar ked

101
110
ill

2.4.2

STAWS

Status

2.4.3

2

6

2

contains a controller-identifier

val~e

of

$FD

STAWS BUFFER

The Status Buffer contains more detail than what is normally shown by the
Status In instruction. The Status Buffer is read by using the ldA39D Write
Control instruction. There are 18 bytes in the Status Buffer, designated as
shCMIl below:
Byte 0:

Controller M:rle (in hex)
1 - disk I/O mode
2 - tick scan mode
3 - menory I/O mode
4 - user mode
5 - format drive mode
6 - read map mode
7 - set drive characteristics mode
8 - diagnostic mode

Byte 1:

User selected options

$80 - generate completion interrupt
$40 - clear tick on read and write
$20 - verify instead of write
$10 - initiate automatic read of next sector
(remaining bits are reserved)
Byte 2:

user selected options
assign alternate on write error
assign alternate on next write
search al.ternate map if sector is marked or read error
bypass verify after write
allow access to reserved sectors
$04 - retry on error
(remaining bits are reserved)
~~re

$80
$40
$20
$10
$08

-

Byte 3:

Completion status byte (upper 3 bits only)
(see status byte 0 description)

Bytes 4-5:

Binary read error counter (total)

11/03/83 PAGE

Bytes 6-7:
Bytes 8-10:
Bytes 11-14:

Binary write error counter (total)
Binary sector address of last operation
Physical sector address of last operation

Byte 15:

Status byte A (additional status)
$80 - (reserved)
$40 - CRC error of compare error
$20 - Sector marked
$10 - Sector found in alternate map
$08 - New alternate entry made
$04 - Invalid sector number
$02 - Control error
$01 - Header mismatch

Bytes 16-17:

Interlace parameter

7

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CONFIGURATION

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P4

11/03/83 PAGE

1

FAGIE UPGRADE PHX::EIJ.JRE

1.

2.

Removal Of Current Drive From System 64 Cabinet.
A.

Lock the heads and motor clamp.
Fujitsu.

Refer to the Black Book Section on

B.

Remove the BUSS, Radial, and Disc Ready Cables.

c.

Disconnect the power cables.

D.

Remove the existing cable retractors.
for the Eagle.)

E.

Fully extend the dr i ve on its rails until the slide locks engage. 'lb
remove the drive from the rails, depress the b.O buttons on each side
of the drive that are located about half-way down the length of the
slide. Continue fUlling the drive, while supporting it, until it is
free from the slides.

F.

Turn the dr i ve on its side and lock the spindle

G.

Rernove the associated power sUWly. If no other disk power supplies
remain, also remove the fX)Wer supply mounting hardware.

H.

Remove the rail slides.

I.

All removed hardware must be packaged for return.

(All new hardware is required

0

Do oot fUt the pc:1Ner
supply or loose hardware in the same box with the disk drive as damage
may result to the dr i ve.

Installing The New Hardware

A. The rails and slides should have been shipped on the Eagle.
slides from the drive.

B.

Remove the

See Figure I-I. Systems shipped with Eagles have had the order in
which they are nounted in the cabinet reversed. The first disk is rrM
directly helCM the tape drive and the second disk is at the. base of the
system.
Use Holes 21-24 For The 1st Drive

Use Holes 3-7 For '!he 2nd Drive

C.

Using Figure I-2 mount the rail slides as shown.

Note:

The front of the slides mount differently

~~en the assewbly
that was just rerroved. The slide now rrounts in front of the
rack instead of behind it.

11/03/83

p~

2

D.

Refer to Figure I-3. Attach brackets A and X to the plastic cable
retractor as shown. Attach bracket X to system frame one or two holes
above the rail slide.

E.

Slide the Eagle onto the rails.
Qill!ION:

This is a three or four person job.
lbs.

The Eagle weighs 140

F.

Attach Bracket A to rear of drive as shown.

G.

Details for routing cables appear in the Eagle Installation Section
(attached) •

H.

If this system is one of the first 20 shipped, you will need to replace
the System Control Panel. The reason for this is the differeoce in
cormectors for the DISC READY Lamps. New systems are shipped with two
sets of DISC READY connectors. The small connectors are for the 168 MB
and 84 MB Fujitsu. The large connectors are for the Eagles.

I.

To replace the control panel renove the four (4) phillips head screws

as shown in Figure I-4. If only a harness was sent use wiring diagram
belaY' for proper installation.
Proceed to the following section:
INSTALIATICN PIaEDRES FOR THE FAGIE DISK DRIVE

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11/03/83 PAGE

1

INSTALIATICN PRXEllRES FOR THE FAGLE DISK DRIVE

SHIPPThJG RESTRAINTS
1.

Remove the system side panels.

2.

The drive is held in place on its rails by a single nut and bolt (See
Figure 0-1). Remove this assembly.

3.

Fully extend the drive on its rails.

4.

Remove the top cover by removing the four screws located on each corner of
the cover. (See Figure 0-2.)

5..

a) 'lb remove the Vibration Damping Block, the card cage must be laid on
its side. Remove the two screws at the base of the card cage (located just
above the rail). (See Figure 0-3.) Pull up on the card cage and lay it
over on its side ..
b) The foam block should rON be visible. It is removed by lifting the
Disk Enclosure slightly and p..111ing the block out towards the card cage.
The dr i ve should rON be resting on its shock nounts.

6.

The final restraint is the head lock.

CABLING

See detail "c" of Figure 0-4.

(Refer to Figures 0-5 and 0-6 for all of the foilONing steps.)

1.

Radial Cable to CNP43.

2.

Buss Cable to Jl of the Power Sequencing Card.

3.

PaYer Sequencing Card to CNP41 of the Inter face Board.

Ground Strap to

mI.
4.

Power Sequencing Harness Assenbly to QJP42. Brown and White twisted pair
extends from the left end of CNP42.
Figure 0-1 shows how to route cables
on retractor assembly.

5.

Run the Disc Ready Cable from the Eagle Front Panel along the bot tom of the

chassis and out fran underneath the Interface Board with the red strip
facing the rail. (See Figure.0-7.) The Disk Ready Cable should be' routed
as shown in Figure I-2.
Note the slack loop midway across the rail. The
first drive plugs into the Wht/Grn and WhtjRed twisted pair. The 2nd drive
plugs into the red/yellow twisted pair. The ~ smaller connectors are
used for the 168 MB or 84 MB dr i ve.
6..

AlC. See Figure 0-8 (AC Wiring Diagram). Example: DrSKl goes to 'IB2-6B

11/03/83 PAGE

2

and TB3-6B and GND to lug E6. The A!e cable provided is much too long.
See Figure 0-8.1 and note that cable is looped and tied to the system

frame.

1.

Interface Board: Set drive address switches to OFF.
always o. (See Figure 0-6.)

2.

Figure 0-9 shows the location of the Logic PCB. Using Extractor Tool (see
Figure 0-9.1), rerrove the IDgic PCB. Card Extractor is to remain with the
drive at all times. 00 NOr RElvDVE.

3.

Using E:igure 0-10 verify or set mini-jurrps to match drawing. OC7-BF7 set
the Bytes Per Sector and Sectors Per Track. WEJ7 sets the interface control
options.

4.

Power Sequencing/Terminator board has two pin patches.
0-11.

Drive address is

Refer to Figure

J2 Configurations:

a. Only one Eagle in system- JLlIIP 1-3 and 2-4.
b. If 2nd Eagle in system- Renove pin patches and plug
Brn/Wht twisted pair from first drive onto J2, pins 1
and 2. Connector is offset so that it can't be put
on backwards.
c. If using Auxilary cabinet, continue this sequence for
any additional Eagles.
d. The twisted pair coming from the laSt dr i ve in the
string should be coiled and tie wrapped to the system

frame.
PCMER SUPPLY

(Refer To Figure 0-12 for the following steps.)

1..

Set the I.Dcal,lRenote switch to the IDeal position.

2.

Set the Main Line switch to the CN position.

DRIVE FIDNT PANEL

(Refer To Figure 0-12.1.)

1.

Set STARr to CN. All Eagles are to be left ih the CN ?",.sition. The ~r
sequencing boards will cycle the drives up when the system is powered on.

2.

Set Protect to OFF.

11/03/83 PAGE

3

AUJUSTMENTS/CHOCKS
1. - VOIATAGES

2.

A.

Measurerrents are made at the backplane of the card cage.
0-13.)

(See Figure

B.

Voltages are adjusted on the power supply to within the tolerances
shown on Table 13.1.

SERVO ADJUSlMENl'S

A.

The drive was shipped properly aligned. The exact policy and
procedures are currently being reviewed. Until further notice DO NOT
ATrEM?T to align the servos on the Eagle drive.
Note:

The above statement against aligning the servos applies to
ali, including those who may have been trained.

1 ..

ATP's have been shipped to the field on the drive.

2.

Run DISC54

3.

00 NO!' FORMAT the drive. The alternate sector map will be destroyed.
Attached to each Eagle drive is a tape containing a ropy of the alternate
sector map. There can be as many as 500 alternate sectors from the
factory. The ATP used to read this tape onto the disk is rot currently
working, however it will be soon. Leave the tape with the drive at all
times.

4.

Do

to verify that the drive is operational.

not bump the disc while it is running. Errors have been observed from
the slight shock to the drive. This should not be encountered unless the
disc is extended for installation or maintenance.

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DC power supply unit

Operator
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LOOSEt-J SCREW 1 A" (BY MEANS OF A PHILLIPS SCREWDRIVER,S" OR !l>NGER)~~" SUFFI~I.ENTLY
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Switch Position

Drive Address

I

1

-.

3 ..

0

OFF

OFF

1

ON

OFF

OFF

2

OFF

ON

OFF

3

ON

ON

OFF

OFF

OFF

ON

5

ON

OFF

ON

6

OFF

ON

ON

7

ON

ON

ON

I

4

(1)

2

.

4

OFF

Not
Used

INTERFACE PCB ----- DQEMU (B16B-B140-0010A#U)

Drive logical address 0 to 7 can be set with three positions of the switch in
binary code as shown in Table 3.2-1.

CNP44

CNP4S

Drive Address Switch

fJ;J
G/;(.{

('

Unit Cable -----~
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Bus Cab Ie ---------

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TABLe NO.2
JUMliEfq TEtlMINATION

• ~1.

NOTU' UNLUS OTtII:nWISI! srECI'.ED
'HANTON LINU INDICAT! 'UfUU
0' TIONAl VI'IIIIONI

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TO
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TO

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TI t-'A

nOM fit ,-,,,

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• 6 tit ....

1A0M U,~u nOM U t·.",
fO " ... , ..
to TI 'ioU

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"1·14

to ttt ....

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to

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fI

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tet-u

to UI-UI

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180YAC

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Interface PCB (DQEMU)
Indicator unit (IIGAMU)

DE

1)(' power supply unit

Operator
panel

'--'

R/W PCB (RFJAU)
Logic PCB (51 2398U)

Servo PCB (SVIAU)

(b)

New version

Card Cage

/-

/

---

~-

-------..

.

0

/---

-------

-------

PCB

PCB Removal

Figure

(1)

Interface Changing

The interface can be changed by shorting the appropriate pins with jumper plugs,
as shown below.
Table 3.3-1
Item
Incorporate
TAG4, 5
Status Capability
Operation of
Seek End status

Interface Selection

Pin number to
be shortened

Default
mode

-

0

03

02

Enable
Disable

03 - 04

~~

-

Seek End is not issued after
Offset Command is reset.

05

"'..,
uo - UI

Response of Unit
Ready

Function

0

.

10 - 09 •

10 - 11

II

0

...

••
",.f=r.o.,...
Seek End 1S
Offset Conunand is reset.
~~",
~rl
..Lo;::,uc;:.u.

CI...L ....

~

....

Unit Ready is issued even if
the drive is in a fault
condition.
Unit Ready is not issued \o:hen
the drive is in a fault
condition.

F~O-~,l

k~~rJ5~
.a.u.....o.a~~

LOGIC
PCB

,
t(J,

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4:,

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.- -."
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-,,' ......

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...- . - .
,-

--/

7.

.....

-

,

.:.

-.

'-':

.

REMOVE THE LOGIC PCB FROM THE CARD CAGE.

.

''','-

" .........

. ..... -........ ..
,

'

.. : -

"o.

BD7 .- .. ; '.~ .' " -2-3, .5-6,' 10-11, 13'::"14.
-

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--

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-

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. .

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. . . . :~;~:/.,:-' .'.::. ~.":}~ ..-' . "-).,~~~:~;:\~~ .'. -", .

:~·c'.~: ..: 2.' ~<

.....

,<

•

. . .-..,. . . .

INSTALL INTERFACE MODIFICATION JUMPERS IN THE FOLLOWING LOCATIONS: -~"-.,
... LOC. AE7

10.

JUMP! '2-3, 6-7, 9-10

REPLACE THE LOGIC PCB IN THE CARD CAGE.

n

ON DRIVER PCB (VENDOR
TVKMU) LOCATED BEHIND THE FRONT PANEL, PLACE
REVISION LABEL (7) ON THE RIGHT OF THE COMP ON ENT4 51-DE, AND'MARK AT RE~. "A".
ON DRIVER PCB (VENDOR 'II TVLHU) LOCATED BEHIND THE FRONT PANEL, PLACE
REVISION LABEL (7) ON !HE END NE~ST.THE-bpERATOR PANEL, AND J:1ARK AT
.

.

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DC POWER SUPPLY UNIT
Control panel of the DC power supply unit is shown in Figure 301-1.

(lj-S.2VAdj0-12VAdJ
(l)-4VAdj 0+12VAd
REMOTE

Cfr> f-

TRM2

LOCAL

(J

SG
FG2

-,
AU•
...J

(FI)
MAIN LINE SWITCH

(1)

O.SA

Cf1dldj)~
lOA

Figure 3.1-1

LQ~J

~~B FAD~

FGl

e

0+SV Adj

ON

fE]

Control Panel of DC Power Supply Unit

Main Line Switch (Non-Fuse Breaker)

Supplies AC power to the unit.

If one of following failures occures, it goes off.

Over current in the AC input
- Over current or voltage in the DC output
- Fan (Line-Blower) Alarm
- Over Temperature of the heat sink or of the transformer in the DC power
supply unit.
(2)

Fan ALM (Fuse)

Indicates fan
(3)

alarm~of

the

line-b~ower.

Remote/Local (Switch)

When this is set to Remote, the spindle motor starts/stops rotating in accordance

+0

-f/v... d .. i v-c..', f,.,~ -/. ('''..,,( .

'- yz; I n r! H~ 11 fi fi] ~Q
~ ~ r 8 fi ~V~ n ~~ t\ 1\ t

O-J2-

Volt ADJ (Variable Resistors)
Although adjustment should not be required, variable resistors are provided to
adjust the -5.2, -4, ±12, -5 Vdc output voltages within the tolerance specified,
if necessary.

OPERATOR PANEL

Switches and indicators on the operator panel are shown in Figure 3.5-1.

EJ~
Fault

Stut

~ IE]]

Power on

(1)

On

On

~~
Protect

Star1

Ready

Start-On (Switch)

When the Remote/Local switch on the control panel of DC power supply unit is set
to Local, this switch enables rotation of the spindle motor.

The heads start

Initial Seek operation and stop on the cylinder zero, approximately 40 seconds
later, lighting the Ready lamp.

The spindle motor stops rotating approximately

15 seconds after the switch is set to off position.
When the Remote/Local switch is set to Remote, the spindle motor starts and stops
rotating in accordance with the Power Sequence Pick/Hold commands issued from the
controller if the Start switch is On.
(2)

Protect-On (Switch)

Inhibits Write operation.

If a write command is issued from the controller while

the switch is On, the Fault and Control Check conditions will be returned to the
controller.
(3)

Start (LED)

Indicates that the spindle is rotatingm

(4)

Ready (LED)

Indicates that the spindle has reached the rated speed and no fault condition
exists in the drive.
cylinder.

It goes off when the heads are seeking to the desired

(5)

Fault (LED and Switch)

Indicates a Fault condition (i.e., R/W check status) or a Seek Error.
Depress~ng

(6)

the indicator switch clears this condition.

Power On

Indicates that the DC power supply unit is on.

.J

Adjustment of DC Voltages
Che~~

the DC voltages at the check pins of Back Panel (BQGMU) using cigital

multimeter.

The check pins' configuration is shown in Figure 13.9-2.

If a DC

voltage is out of the acceptable range of Table 13.9-1, readjust the corresponding
RV shown in Figure 13.9-1.

use this pin as SG.

I

B16B-8160-0010A
/
~ -4V
~~------------QG--M-----------------------'
~ -S.2V
~;~v.J
B
u

~-12V

Figure.

Table

13./

DC

Voltage

+12 V
+5 V

0

OV'

~

(

GI'1['

+UV

0-/3 Top View of Back Panel
Acceptable Range of DC Voltages

Acceptable

11.4
4.75

'\,

'\,

Range

12 .. 6 V
5.25 V

'\, -4.2 V

-4 V

-3.8

-5.2 V

-4.94 '\, -5.46 V

-12 V

-11.;

'\, -12.6 V

0-/3



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