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Cray T3E Manual

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AC Repair and Adjustment Procedures
HMM-168-A.1
CRAY T3E™ Air-cooled Systems
Last Modified: January 1998
Record of Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Doors and Panels
FRP 1: Opening and Removing the Cabinet Doors . . . . . . . . . . . . . . . . . . . . . .
FRP 2: Removing the Cabinet Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module Power Supplies, Modules, Daughter Cards, and Rails
FRP 3: Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 4: Auxiliary Clock Power Supply Replacement . . . . . . . . . . . . . . . . . . . .
FRP 5: Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 6: Daughter Card Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 7: Power Supply Rail Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 8: Top Module Rail Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 9: Bottom Module Rail Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables
FRP 10: Logic Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 11: GigaRing Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 12: Clock Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 13: Boundary Scan Cable/Wire Replacement . . . . . . . . . . . . . . . . . . . . . .
FRP 14: Module-to-WACS Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . .
Warning and Control System (WACS) and Switches
FRP 15: WACS Microprocessor (EPROM) Replacement . . . . . . . . . . . . . . . . .
FRP 16: WACS Scanner Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
FRP 17: WACS Display Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HMM-168-A.1
Cray Research/Silicon Graphics Proprietary
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Summary of Contents for Cray T3E

  • Page 1: Table Of Contents

    AC Repair and Adjustment Procedures HMM-168-A.1 CRAY T3E™ Air-cooled Systems Last Modified: January 1998 Record of Revision ..........
  • Page 2 Cleaning the EMI Filters ........Adjusting the Module Power Supply Output Voltage ....Cray Research/Silicon Graphics Proprietary HMM-168-A.1...

  • Page 3: Record Of Revision

    Made minor technical corrections elsewhere. March 1998 Revision A.1. Updated the power supply removal procedure with information about the appropriate tools to use in order to avoid stripping hex bolts. HMM-168-A.1 Cray Research/Silicon Graphics Proprietary...

  • Page 4: Introduction

    This document guides you in removing and replacing the field replaceable units (FRUs) of the CRAY T3E air-cooled (AC) cabinet. This document includes a list of FRUs, on-site spares, and tools for the CRAY T3E AC cabinet. It also includes procedures for parts that need periodic maintenance.

  • Page 5: Field-Replaceable Units (Frus), On-Site Spares, And Tools

    AC Repair and Adjustment Procedures Field-replaceable Units (FRUs), On-site Spares, and Tools Field-replaceable Units (FRUs), On-site Spares, and Tools Table 1 lists the field-replaceable units (FRUs) for the CRAY T3E air-cooled (AC) cabinet at the time of publication. Table 1. Mainframe FRUs Cabinet...
  • Page 6 57199100 Switch, Rocker (Cabinet Power / Emergency) 57199101 Switch, Rocker Silver Contacts (Blower Bypass) 57253600 PC Board Assy, T3E Switch (Clock Switches) Fuses 01134006 Fuse, 250V 1/2 Amp (0.5-A WACS scanner fuse) 01158809 Fuse, Ceramic 250V 15 Amp (power supply fuse)
  • Page 7 Contactor, 4 Pole 65 Amp 600V 57170001 Cordset, IEC320 20A 480V Blower, Blower Speed Control Components, and Air Filter 57067701 Controller, Power SCR 20A W/ XFMER (transformer) 57081901 Capacitor, Run 20MFD 57178900 Blower Assy, 18 Inch 57188100 Filter, Air Intake HMM-168-A.1 Cray Research/Silicon Graphics Proprietary...
  • Page 8 Field-replaceable Units (FRUs), On-site Spares, and Tools AC Repair and Adjustment Procedures Table 2 lists on-site spares for the CRAY T3E AC cabinet. Table 2. On-site Spares (57247700) Part Number Description 01134006 Fuse, Glass 1/2 Amp (WACS scanner) 01158809 Fuse, Ceramic 250V 15 Amp (power supply)
  • Page 9 AC Repair and Adjustment Procedures Field-replaceable Units (FRUs), On-site Spares, and Tools For more information on AC spares, refer to the CRAY T3E Spares Support Plan at http://www.csd.sgi.com/spo/T3E/t3espare.htm, which contains lists of country spares, parts bank spares, and central Logistics spares.
  • Page 10 Pliers, Needle Nose 90334800 Tape, Cleaner HD 4MM ME107389 Tool Assy, Daughter Board Removal NOTE: You can modify CRAY Y-MP carts for use with both CRAY Y-MP and CRAY T3E modules by installing two rails, P/N 13267700. Cray Research/Silicon Graphics Proprietary HMM-168-A.1...

  • Page 11: Cabinet Overview

    Cabinet Overview Cabinet Overview Figure 1 shows a front left view of the CRAY T3E AC cabinet without aesthetic panels (i.e., trim or skins) or door. The figure shows access panels, wire ducts, and various cabinet components. Figure 1. Access Panels, Ducts, and Components (Front Left View)
  • Page 12 Figure 2. Access Panels (Rear Left View) Upper Rear Wire Duct Cover Blower Exhaust Shield Upper Plenum Panel Module Panel Lower Plenum Panel Lower Logic Panel Wrist-strap I/O Panel Plugs Cray Research/Silicon Graphics Proprietary HMM-168-A.1...

  • Page 13: Frp 1: Opening And Removing The Cabinet Doors

    CAUTION If you insert a tool in a door opening hole, ensure that the tool does not touch and exert force on the fiberglass. Pressure against the fiberglass will cause it to crack and chip. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 14 2. Use a Phillips screwdriver to disconnect one end of the ground wire that connects to the top of the door. 3. Disconnect the Cabinet Power switch connector (front door only). The connection is near the top left corner of the front door. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 15 3. Carefully lower the door onto the frame hinge pins. 4. Ensure that the door opens and closes properly. 5. Connect the Cabinet Power switch connector (front door only) and the ground wire, then close the door for normal operation. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 16: Frp 2: Removing The Cabinet Side Panel

    4. Disconnect the cable from the clock switch board. Two flathead screws secure the cable to the board. 5. Remove the blower exhaust shield. Six #2 (M4) Phillips screws secure the shield to the cabinet. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 17 Holes for Bottom Retaining Bolts Wire Duct Covers 8. Use a 10-mm socket to remove the nuts and washers from the bottom retaining studs. (Be careful not to drop any nuts or washers into the wire channels.) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 18 Keep the panel in a vertical position. WARNING Remove the panel carefully; the side panel may start tipping. The panel is heavy and will cause injury if it falls on someone. b. Set the panel in a protected location. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 19 AC Repair and Adjustment Procedures FRP 2: Removing the Cabinet Side Panel Figure 5. Removing Side Panels Stud Spacer (Stand-off) Spacer (Stand-off) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 20 3. Reconnect the Cabinet Power switch (SW2) if necessary. 4. Replace the wire duct panels. 5. Replace the blower exhaust shield and connect the clock switches. 6. Return the cabinet to operation, and close the front and rear cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 21: Frp 3: Power Supply Replacement

    Small flatblade screwdriver • 2.0-mm, 2.5-mm, and 3.0-mm hex sockets with torque driver The sockets are included in “Socket set, Hex Bit 1/4” Drive Metric,” P/N 53267200, which is part of the T3E Tool Kit, P/N 15210200. • #1 Phillips screwdriver •...
  • Page 22 When the power supply is halfway out of the cabinet, place one hand on the bottom of the power supply. c. Pull the power supply out of the cabinet. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 23 It is heavy and may cause back injury, or it may cause injury if it falls on someone. 8. Set the old power supply and the replacement power supply on an ESD-safe work area. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 24 FRP 3: Power Supply Replacement AC Repair and Adjustment Procedures Figure 6. Power Supplies and Interlocks – End View Power Supply Step 6 Control In Place Connection Power Cord Retaining Screw Power Supply Step 7 Removed Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 25 Remove any bits of thermal pad left on the heat sink. It is not necessary to remove the white thermal compound (if there is any) from the heat sink; however you should ensure that the compound does not clog any air vents. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 26 Position the heat sink on the power supply; align the bolts (or bolt holes) in the heat sink with the bolt holes on the power supply. c. Install the four 3-mm hex bolts and the associated washers. Tighten the bolts until finger tight. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 27 3. Connect the control connector to the power supply and tighten the retaining screws. 4. Install the power cord: a. Rotate the lower mechanical interlock counterclockwise until the power receptacle is fully exposed. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 28 (switch) on the WACS panel. When you press the Restart button, the WACS sends enable signals to all power supplies with functional modules. This does not adversely affect power supplies that are already powered up. 7. Close the front door of the cabinet. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 29: Frp 4: Auxiliary Clock Power Supply Replacement

    You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the secondary circuit breaker (CB10) that controls power to the auxiliary clock power supply. 4. Disconnect the power cord from the auxiliary power supply. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 30 FRP 4: Auxiliary Clock Power Supply Replacement AC Repair and Adjustment Procedures Figure 8. Clock’s Auxiliary Power Supply – Location Power Supply Circuit Breaker CB10 Main Disconnect (CB1) Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 31 2. Secure the power supply to the top of the WACS box with the 4 Phillips screws and washers. 3. Connect the control cable to the power supply. 4. Connect the power cord to the power supply. 5. Return the system to operation, and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 32: Frp 5: Module Replacement

    Failure to avoid live power components could result in severe shock and burns. NOTE: Refer to FN 2290, CRAY T3E Module and Daughter Card Part Number Reference, for current PEM, clock, and daughter-card part numbers and for details on the following rules: •...
  • Page 33 Insert the metal camming tool in the innermost slot of each camming guide (top and bottom), as shown in Figure 10. Then gently slide the camming tool into the module to uncam the connectors. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 34 FRP 5: Module Replacement AC Repair and Adjustment Procedures Figure 10. Module Camming Uncams Cams Cams Uncams 6. Use a 3-mm hex wrench to remove the retaining screw (setscrew) from the module handle. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 35 Ensure that you do not touch the logic components with your skin or clothing. d. With one hand on the module handle and the other hand supporting the bottom of the module, pull the module from the cabinet. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 36 11. Pack the module in an approved shipping container for return to Chippewa Falls. Refer to “Packing a Module in a Shipping Container” page Figure 12. Pin Protector Retaining Screw Protector Guide Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 37 NOTE: If the PEM jumpers became loose during shipping or handling, refer to FN 2302, CRAY T3E PEM Jumper Positions and Definitions, for replacement information. 1. If necessary, transfer daughter cards to the module. Refer to 2.
  • Page 38 1. Ensure that the defective module contains plastic cams (shuttle connector locks – P/N 12919100) and that all exposed daughter-card pin connectors are covered by pin protectors (P/N 15145700). Figure 13 shows a pin protector. Figure 13. Pin Protector Retaining Screw Protector Guide Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 39 11. Complete the module return kit and label the shipping container (outer box) for return to Chippewa Falls. Follow the instructions provided in the module return kit. NOTE: Remove all previous or old shipping labels from the outer container. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 40 FRP 5: Module Replacement AC Repair and Adjustment Procedures Figure 14. Module Shipping Container – Inner Box Filler Foam Top Die-cut Foam Module in Protective Bag (handle on the right) Bottom Die-cut Foam Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 41 AC Repair and Adjustment Procedures FRP 5: Module Replacement Figure 15. Module Shipping Container – Outer Box HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 42: Frp 6: Daughter Card Replacement

    NOTE: Never mix daughter cards of different memory size on the same PEM. Refer to FN 2290, CRAY T3E Module and Daughter Card Part Number Reference, for more rules and for current PEM, clock, and daughter-card part numbers.
  • Page 43 One strap between the static monitor and the ESD mat • One strap between the static monitor and the module • One strap between the static monitor and your wrist strap Figure 16. Static Monitor and ESD Mat HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 44 6. Lift the daughter-card removal tool (and daughter card) directly away from the surface of the module. 7. Remove the daughter card from the removal tool and place it in an ESD-protective bag. Ensure that you touch only the sides of the daughter card. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 45 8. If you plan to store or ship a PEM, install pin protectors (P/N 15145700) on all exposed daughter-card pin connectors on the PEM. Refer to Figure Figure 19. Pin Protector Retaining Screw Protector Guide HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 46 5. Install the 4 retaining screws that secure the daughter card to the mother board. Tighten the screws to 50 in-oz. each; tighten the screws in an alternating sequence, as shown in Figure Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 47 Retest after you remove each daughter card. Repair any bent pins if possible. If either the daughter card or motherboard is faulty, replace it immediately. 7. Install the module (refer to HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 48 FRP 6: Daughter Card Replacement AC Repair and Adjustment Procedures Figure 21. Ohming the PEM –3.4 Vdc Input Power Bus Ground Bus Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 49: Frp 7: Power Supply Rail Replacement

    Refer to 4. Use the hex wrench to remove the 4 shoulder screws (2 at each end of the rail), then remove the rail from the cabinet. Refer to Figure HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 50 (or a partner) hold the rail in place while you remove the screws. 5. If necessary, cover the air slot with a slot cover. Two #3 Phillips screws hold the slot cover in place. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 51 Tighten the screws securely. 5. Carefully replace the power supplies. (Refer to 3.) Correct any alignment problems. 6. Return the system to operation, and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 52: Frp 8: Top Module Rail Replacement

    0.3-mm mechanical pencil, with no lead (or a wire removal tool) • Hand-held mirror • Flashlight • Tweezers Rail Removal CAUTION Observe all ESD precautions. Failure to do so could result in damage to the equipment. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 53 Use a #1 Phillips screwdriver to loosen the five Phillips screws that secure each air seal assembly. b. Lift the air seal assemblies to provide room for the cable. The air seal assemblies contain slots that move up and down on the Phillips screws. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 54 9. Remove the module where you will replace the rail and remove one or more adjacent modules to provide access to the rail. Refer to 5. Put the modules in a protected location that is ESD safe. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 55 15. Carefully disconnect the clock wires from the defective rail. Removing clock wires is an intricate process; refer to FRP 12 for details. 16. Prepare the wires and cables, which attach to the defective rail, for removal with the rail: HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 56 Be careful not to damage any wires as you remove the rail and attached cables. 20. If necessary, cover the air slot with a slot cover. Two #3 Phillips screws hold the slot cover in place. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 57 Ensure that the plunger does not slip below the brace. d. While you press the plunger against the brace, route the torus cables, clock wires, WACS connection, and boundary scan wires up and through the slot cutout. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 58 8. Carefully replace the modules. Correct any alignment problems. Refer to 9. Reinstall all panels that you removed earlier. 10. Return the system to operation, ensure proper module function, and close the cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 59: Frp 9: Bottom Module Rail Replacement

    1. Open the front cabinet door. 2. Open the cabinet’s main disconnect circuit breaker (CB1) and unplug the cabinet. Place a lockout device over the cabinet’s plug and lock/tag it. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 60 7. Remove the module where you will replace the rail and remove one or more adjacent modules to provide access to the rail. Refer to 5. Put the modules in a protected location that is ESD safe. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 61 11. Remove the shoulder screw from the other end of the rail. CAUTION When you remove a bottom rail, ensure that it does not drop through the slot when you attempt to remove it. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 62 Ensure that you do not pinch any wires or cables between the rail and the card cage. c. Push the plunger on the power supply end of the rail against the brace (crossbar) in the module box. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 63 7. Carefully replace the modules. Correct any alignment problems. Refer to 8. Reinstall all panels that you removed earlier. 9. Return the system to operation, ensure proper module function, and close the cabinet doors. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 64 FRP 9: Bottom Module Rail Replacement AC Repair and Adjustment Procedures Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 65: Frp 10: Logic Cable Replacement

    1. Open the front cabinet door. 2. Open the cabinet’s main disconnect circuit breaker (CB1) and unplug the cabinet. Place a lockout device over the cabinet’s plug and lock/tag it. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 66 9. If the cable that you are removing passes from one cabinet to another, open the cable ducts where the cable passes between cabinets: a. Use a #1 Phillips screwdriver to loosen the five Phillips screws that secure each air seal assembly on the cable ducts. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 67 The screws are P/N 13033501. The brass spacer is P/N 12755600. e. Slide the connector toward the air damper until it clears the other connectors, then pull the connector out of the rail and into the wiremat. f. Remove the cable from the wiremat. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 68 FRP 10: Logic Cable Replacement AC Repair and Adjustment Procedures Figure 24. Slot Guide Screws, Connector Screws, and Slot Foam Nylon Screws (7) Hex Screws (2) Foam Plastic Slot Guide Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 69 Figure 25. Torus Cable Connections Interconnects Rail Rail Connector Connector Connecting P2 to P3 Alignment Guides Socket 20 Socket 1 End View Socket 21 Socket 40 Pin 1 Pin 20 End View Pin 21 Pin 40 Alignment Grooves HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 70 6. Replace and cam the modules that you removed. Refer to 7. Replace any panels that you removed earlier. 8. Return the system to operation, ensure proper function, and close the cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 71: Frp 11: Gigaring Cable Replacement

    1. Open the front cabinet door. 2. Open the cabinet’s main disconnect circuit breaker (CB1) and unplug the cabinet. Place a lockout device over the cabinet’s plug and lock/tag it. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 72 11. If necessary, swing the I/O bulkhead on its hinges to provide access to the wiremat. Use a #1 Phillips screwdriver to remove the 8 screws that secure the I/O bulkhead in operating position. Pull the top of the I/O bulkhead toward you. Refer to Figure Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 73 The screws are P/N 13033501. The brass spacer is P/N 12755600. 15. Slide the connector toward the air damper until it clears the other connectors, then drop the connector out of the rail and into the wiremat. 16. Remove the cable from the wiremat. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 74 Position the connector in the connector slot, and insert the hex screws (and brass spacer if applicable). Tighten the screws to 15 in-oz. c. Push the connector toward the spring to ensure that the connector moves laterally then springs back into position. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 75 5. Swing the I/O bulkhead into operating position and secure it with screws. 6. Replace and cam the modules that you removed. Refer to 7. Replace any panels that you removed earlier. 8. Return the system to operation, ensure proper function, and close the cabinet doors. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 76: Frp 12: Clock Wire Replacement

    Dental pick • Tweezers (optional) • Hemostats (forceps) or another wire insertion tool (all optional) • Cutters/snips Wire Removal CAUTION Observe all ESD precautions. Failure to do so could result in damage to the equipment. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 77 NOTE: If the clock wire that you are removing passes from one cabinet to another, you must access the wiremats in all appropriate cabinets. In addition, you must open the intercabinet cable ducts as described in the following step. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 78 Secure the air seal assemblies in the open position by tightening the Phillips screws on the assemblies. Figure 28. Intercabinet Cable Ducts (as viewed from the inside of the cabinet) Closed Cable Duct Duct Seal Duct Seal Retaining Screws Open Cable Duct Foam Strips Open Duct Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 79 Then loosen (but do not remove) the remaining hex screw in the adjacent connector that is closer to the power supply. Refer to Figure 30. Be careful not to lose any screws; set the screws in a secure location. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 80 Place the spring in a secure location. NOTE: Removing the spring ensures that you do not accidently wrap a wire around the spring when you reinsert the connector. If you guard against this, you may leave the spring on the rail. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 81 17. Use a 0.3-mm mechanical pencil (or a wire removal tool) to release the clock wire from each rail connector: a. Position yourself so that you can see the clock wire pins. b. Identify the pin location of the defective wire. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 82 If you cannot remove the defective clock wire, cut off the other end of the defective wire as well, to avoid potential confusion at a later date. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 83 Press the top of the Gently push the Move the clock wire Step 5 connector to fully clock wire connector connector to the seat it in the rail into rail connector. appropriate location. connector. Rail Connector HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 84 7. Ensure the proper orientation of the connector, then position the connector in the connector slot, and insert the hex screws (and brass spacer if applicable). Tighten the screws to 15 in-oz. 8. Install the spring and center it in relation to the connector block. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 85 13. Replace and cam the modules that you removed. Refer to 14. Reinstall any panels that you removed earlier. 15. Return the system to operation, ensure proper function, and close the cabinet doors. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 86 The cavity pinches the pins together as you insert the connector. 2, 3, & 4. Pull the rod through the connector block to insert the 2-pin connector. If necessary, seat the connector with your fingertip. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 87: Frp 13: Boundary Scan Cable/Wire Replacement

    • Medium flatblade screwdriver • 0.3-mm mechanical pencil without lead (or a wire removal tool) • Multimeter • Flashlight • Dental pick • Tweezers (optional) • Hemostats (forceps) or another wire insertion tool (all optional) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 88 6. Loosen the eight 1/4-turn captive screws that secure the module panel, then pull the module panel out of the cabinet at an angle. 7. Remove the upper plenum panel to provide access to the wire assembly. Six #1 Phillips screws hold the panel in place. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 89 13. Use tweezers or your fingers to carefully remove the foam plug (P/N 57176200) from the slot where the wire assembly enters the rail. (Each connector slot contains an oval piece of foam, which tears easily.) Refer Figure HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 90 Refer to Figure 38. Be careful not to lose any screws; set the screws in a secure location. The screws are P/N 13033501. The brass spacer is P/N 12755600. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 91 Place the spring in a secure location. NOTE: Removing the spring ensures that you do not accidently wrap a wire around the spring when you reinsert the connector. If you guard against this, you may leave the spring on the rail. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 92 19. Use a dental pick (or some other sharp tool) to carefully remove the plastic pin lock (P/N 01775900) from the module side of the connector. Refer to Figure 40. (You will replace the pin lock with a new one.) Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 93 Refer to Figure Return to the wiremat and pull the defective wire assembly from the rail. 21. Remove the defective wire assembly from the cabinet. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 94 Push the 2-pin point of the pencil pencil so that the connector out of over the outer pin. outer pin bends the rail connector. toward the inner pin. This releases the pin lock. Rail Connector Pencil Latch Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 95 Figure 42. Wire Insertion Move the connector Gently push the Press the top of the Step 5 to the appropriate connector into rail connector to fully location. connector. seat it in the rail connector. Rail Connector HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 96 Figure 43. Inserting and Seating a Plastic Connector Pin Lock Place curve of dental pick between the 2 rows of pins and slide it back and forth. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 97 14. Replace and cam the modules that you removed. Refer to 15. Reinstall any panels that you removed earlier. 16. Return the system to operation, ensure proper function, and close the cabinet doors. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 98 The cavity pinches the pins together as you insert the connector. 2, 3, & 4. Pull the rod through the connector block to insert the 2-pin connector. If necessary, seat the connector with your fingertip. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 99: Frp 14: Module-To-Wacs Cable Replacement

    0.05-in. hex (allen) wrench with torque driver • 0.3-mm mechanical pencil, with no lead (or a wire removal tool) • Flashlight • Dental pick • Tweezers (optional) • Hemostats (forceps) or another wire insertion tool (all optional) • Cutters/snips HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 100 Remove the I/O panel, loosen the I/O bulkhead, and remove the lower plenum panel. (Eight 1/4-turn captive screws secure the I/O panel to the cabinet. Six #1 Phillips screws hold the I/O bulkhead in place. Twelve #1 Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 101 Then loosen (but do not remove) the remaining hex screw in the adjacent connector that is closer to the power supply. Refer to Figure 46. Be careful not to lose any screws; set the screws in a secure location. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 102 Removing the spring ensures that you do not accidently wrap a wire around the spring when you reinsert the connector. If you guard against this, you may leave the spring on the rail. Figure 47. Removing a Connector Spring Spring Tweezers Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 103 Refer to Figure d. Return to the wiremat and pull the wire from the rail. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 104 Swing the I/O bulkhead toward you to expose the panel behind it. Locate the clock-to-WACS cable connection. Note that you must disconnect the cable from the other side of the panel as described in the following steps. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 105 If possible, have a partner check your work. d. Carefully press the top of the connector to fully insert the connector. CAUTION Ensure that you do not damage the wires when you insert the connector. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 106 12. Use a small flatblade screwdriver to connect the WACS harness connector to the cable that you just installed. 13. Replace and cam the modules that you removed. Refer to 14. Reinstall any panels and parts that you removed earlier. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 107 15. Return the system to operation, ensure proper function, and close the cabinet doors. Figure 51. Inserting and Seating a Plastic Connector Pin Lock Place curve of dental pick between the 2 rows of pins and slide it back and forth. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 108 The cavity pinches the pins together as you insert the connector. 2, 3, & 4. Pull the rod through the connector block to insert the 2-pin connector. If necessary, seat the connector with your fingertip. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 109: Frp 15: Wacs Microprocessor (Eprom) Replacement

    FRP 15: WACS Microprocessor (EPROM) Replacement FRP 15: WACS Microprocessor (EPROM) Replacement Be careful not to damage any WACS components during this procedure. Part Number • 15135900 (IC, micro T3E air WACS) Tools Required • Extractor, PLCC 20-84 pin (P/N 15255000) Microprocessor Removal CAUTION Observe all ESD precautions.
  • Page 110 Instead, squeeze the tool handles until the microprocessor separates from the socket. e. When the microprocessor separates from the microprocessor socket, remove the microprocessor from the cabinet and insert it in an ESD-protective bag for return to Chippewa Falls. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 111 AC Repair and Adjustment Procedures FRP 15: WACS Microprocessor (EPROM) Replacement Figure 53. WACS Microprocessor Removal HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 112 2. Close the WACS panel; rotate the two latch screws counterclockwise to secure the panel. 3. Power up the cabinet and check WACS function. 4. Close the front cabinet door. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 113: Frp 16: Wacs Scanner Board Replacement

    FRP 16: WACS Scanner Board Replacement FRP 16: WACS Scanner Board Replacement Be careful not to damage any WACS components during this procedure. Part Number • 31504104 (module assembly, IOSF/T3E air WACS) Tools Required • Flatblade screwdriver • #1 Phillips screwdriver...
  • Page 114 It may help to pull one end out first and then the other. 10. Remove the 6 Phillips screws (and washers) that hold the scanner board. Hold the scanner in place while you remove the last 2 screws. Hold the Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 115 The connectors are tabbed so that you can insert them one way only. 6. Close the WACS panel. Rotate the two latch screws counterclockwise to secure the panel. 7. Power up the cabinet and check WACS function. 8. Close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 116 FRP 16: WACS Scanner Board Replacement AC Repair and Adjustment Procedures Figure 55. Connecting the Power Strip Scanner Portion of Power Strip Power Strip Step Position the Power Strip Step 4b Press Together Step 4c Seat Fully Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 117: Frp 17: Wacs Display Replacement

    1. Open the front cabinet door. 2. Open the WACS panel and locate the display board. 3. Disconnect the WACS connector (Amp-modu connector) from the defective WACS display: HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 118 WACS panel, then remove the WACS frame (and display) from the cabinet. Refer to Figure 5. Use a #1 Phillips screwdriver to remove the 4 screws that hold the display board to the display frame. 6. Remove the defective display connector. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 119 4. Connect the WACS display connector: push the connector horizontally into the display-portion of the connector until the side latches snap into place. 5. Close the WACS panel. 6. Ensure that the display operates properly. 7. Close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 120: Frp 18: Wacs Panel Switch (Sw6, Sw7, Sw8) Replacement

    4. Record the locations of the wires that connect to the switch. NOTE: You will leave the wires on the switch until you release it from the WACS panel. You will then transfer the wires to the replacement switch. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 121 WACS panel. The flanges on the switch will lock the switch in place. 3. Close the WACS panel. 4. Return the cabinet to operation and check the switch function. 5. Close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 122: Frp 19: Blower Controller Bypass Switch (Sw3) Replacement

    (SCR1). Four screws hold the panel in place. 5. Use a small flatblade screwdriver to depress the top flange on the switch as you push the top of the switch through the cutout (switch hole) in the WACS box. Refer to Figure Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 123 3. Replace the panel that covers the blower controller (SCR1). Four #2 Phillips screws hold the panel in place. 4. Return the cabinet to operation, and check the switch function. 5. Close the WACS panel. 6. Close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 124: Frp 20: Cabinet Power Switch (Sw2) Replacement

    8 hex screws that attach the EMI filter to the door.) 4. Use a #2 Phillips screwdriver to remove the aesthetic panel from the front door, and set it in a protected location. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 125 3. Replace the switch box. 4. Apply power to the cabinet and check the switch function. 5. Replace the aesthetic panel and the EMI filter. 6. Close the front door. 7. Return the cabinet to operation. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 126: Frp 21: Clock Switch Board Replacement

    If a Clock Select switch or the Boundary Scan Enable switch fails, you must replace the entire clock switch board. Part Number • 57253600 (PC board assembly, T3E switch -- clock switch board) Tools Required • Small flatblade screwdriver •...
  • Page 127 6. Use a 7-mm wrench to remove the 4 nuts that hold the switch board to the blower exhaust shield. 7. Remove the switch board. Figure 60. Clock Switch Board Cover Plate Screws Switch Nuts Exhaust Shield Switch Connector HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 128 3. Connect the cable to the clock switch board and tighten the 2 retaining screws with a small flatblade screwdriver. 4. Return the cabinet to operation, check the switch function, and close all cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 129: Frp 22: Module Thermistor Replacement

    Observe all ESD precautions. Failure to do so could result in damage to the equipment. 1. Identify the defective thermistor. 2. Remove the module from the cabinet using 3. Set the module (heat sink down) on an ESD-safe surface. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 130 Allen Screw Power End of PCB Handle End of PCB 5. Use the 4-mm hex wrench to remove the allen screw that secures the thermistor to the PCB. 6. Remove the thermistor from the module. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 131 PCB. Tighten the screw finger tight. 2. Plug the 2-pin miniconnector into the thermistor connector. 3. Install the module in the cabinet (refer to 4. Return the cabinet to operation, check thermistor function, and close the cabinet doors. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 132: Frp 23: Inlet Air Thermistor Replacement

    You may also open, lock, and tag the customer’s wall breaker(s). 4. Use a #1 Phillips screwdriver to remove the lower wire-duct panel, where the thermistors mount. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 133 63): Carefully use a small flatblade screwdriver to pry the connector lock on the wire end of the thermistor connector so that it releases the miniconnector. At the same time, gently pull the miniconnector out. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 134 3. If you removed the connector from the connector bracket, reinstall it by pushing it into the bracket until the side flanges lock in place. 4. Connect the thermistor connector to the WACS harness. 5. Connect the thermistor to the panel with the nylon screw. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 135 WACS display. Then apply heat to the new thermistor (for example, apply body heat with your hand) and check the temperature change on the WACS display. 7. Replace the panel, return the cabinet to operation, and close the door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 136: Frp 24: Exhaust Air Thermistor Replacement

    Heat gun (optional) Thermistor Removal 1. Open the front cabinet door. 2. Open the cabinet’s main disconnect circuit breaker (CB1) and unplug the cabinet. Place a lockout device over the cabinet’s plug and lock/tag it. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 137 WACS harness up to disconnect the thermistor connector from the WACS harness. Refer to Figure 5. Remove the four #2 Phillips screws that secure the thermistor plate to the ceiling of the module exhaust plenum. Refer to Figure HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 138 Figure 64. Releasing the Thermistor Connector Step 4 From Release WACS Lever Harness Step 7 Side Flanges Thermistor Connector Figure 65. Exhaust Air Thermistors View from Cabinet Rear Thermistor Primary Thermistor Screw Plate Thermistor Connector View from Top Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 139 3. Position the thermistor plate in the cabinet, and push the thermistor connector through the hole in the ceiling of the module exhaust plenum. 4. Connect the thermostat wires to the thermostats, and connect the thermistor connector to the WACS harness. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 140 9. Replace the upper plenum panel and the module panel. 10. Replace the blower exhaust shield and attach the cable to the clock switch board. 11. Return the cabinet to normal operation, and close both cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 141: Frp 25: Thermostat Replacement

    Heat gun (optional) Thermostat Removal 1. Open the front cabinet door. 2. Open the cabinet’s main disconnect circuit breaker (CB1) and unplug the cabinet. Place a lockout device over the cabinet’s plug and lock/tag it. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 142 5. Determine the location of the defective thermostat. (Use an ohmmeter to test the thermostats if necessary.) 6. Disconnect the wires from the defective thermostat. 7. Use a #1 Phillips screwdriver to remove the 2 screws that hold the thermostat, then remove the thermostat. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 143 6. If a heat gun is available: a. Have a partner watch the exhaust air temperatures on the WACS display, while you use a heat gun to heat the thermostat to approximately 150 ˚F (65 ˚C). HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 144 7. Replace the upper plenum panel and the module panel. 8. Replace the blower shield and connect the cable to the clock switch board. 9. Return the cabinet to normal operation, and close both cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 145: Frp 26: Wacs Scanner Fuse Replacement

    You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the WACS circuit breaker (CB9). 4. Open the WACS panel and locate the defective scanner fuse. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 146 SWS NWACS display is driven by scanner B.) WARNING Components within the WACS box receive line voltage. Do not contact them. Failure to avoid these components could result in severe shocks and burns. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 147 11. If the fuse blows again, troubleshoot a possible power problem. If the input power to the scanner is acceptable, replace the WACS scanner. 12. Restore the cabinet to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 148: Frp 27: Power Supply Fuse Replacement

    5. Install the replacement fuse(s). (Ensure that replacement fuses meet the required specifications.) 6. Reconnect the power cord to the power supply, close the circuit breaker for this power supply, and press the Restart switch to enable power to this power supply. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 149 FRP 27: Power Supply Fuse Replacement Figure 69. Power Supply Fuses Fuse Caps 7. Check the WACS display to ensure a proper power supply output. 8. Restore the cabinet to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 150: Frp 28: Blower Control Fuse Replacement

    3. Open the blower circuit breaker (CB8). 4. Open the WACS panel. 5. Remove the fuses, one at a time, and check for continuity with an ohmmeter. (Use a flatblade screwdriver to remove the fuse cover.) Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 151 9. Restore the cabinet to operation, and close the front cabinet door. 10. Periodically, check the cabinet and module temperatures to ensure proper blower speed control. Figure 70. Blower Control Fuse Locations Fuses HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 152: Frp 29: Main Disconnect Circuit Breaker (Cb1) Replacement

    Place a lockout device over the cabinet’s plug and lock/tag it. WARNING Ensure that the electrical plug for the equipment that you service is unplugged, locked, and tagged. Failure to do so could result in severe shock and burns. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 153 Use the same technique to open the right spring latch, then rotate the circuit breaker up and off the DIN rail. 8. Use the #2 Phillips screwdriver to remove the output (load) wires from the circuit breaker. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 154 FRP 29: Main Disconnect Circuit Breaker (CB1) Replacement AC Repair and Adjustment Procedures Figure 71. Removing CB1 Step 7 Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 155 6. Position the circuit breaker so that it aligns with the hole in the power box cover, then replace the cover and secure it with screws and washers. 7. Replace the air filter. 8. Restore the cabinet to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 156: Frp 30: Wacs Panel Circuit Breaker (Cb8, Cb9, Or Cb10) Replacement

    You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the WACS panel. 4. Note the positions of the wires that connect to the defective circuit breaker. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 157 DIN rail. d. Now lift the top portion of the circuit breaker out of the DIN rail. 7. Use the #2 Phillips (or flatblade) screwdriver to remove the wires from the top of the circuit breaker. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 158 1. Ensure that the screw clamps (wire cages) in the replacement circuit breaker are open. 2. Refer to your record of the wire locations while you insert the wires into the top of the circuit breaker. Hold the breaker firmly and tighten the screw clamps securely. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 159 6. Position the circuit breaker so that it aligns with the hole in the WACS panel, then close the WACS panel. 7. Close the circuit breaker. 8. Return the system to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 160: Frp 31: Power Supply Circuit Breaker (Cb2 Through Cb7) Replacement

    Failure to do so could result in severe shock and burns. You may also open, lock, and tag the customer’s wall breaker(s). 3. Remove the air filter. Refer to FRP 37 for removal instructions. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 161 DIN rail. d. Lift the top portion of the circuit breaker out of the DIN rail. 8. Use the #2 Phillips screwdriver to remove the input wires from the top of the defective circuit breaker. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 162 Insert the upper portion of the circuit breaker into the DIN rail. b. Use the flatblade screwdriver to open the spring latch, then rotate the circuit breaker into place and release the spring latch. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 163 6. Position the circuit breaker appropriately, then replace the breaker box cover and secure it with screws and washers. 7. Replace the air filter. 8. Return the system to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 164: Frp 32: Voltage Selector Switch (Sw1) Replacement

    3. Remove the air filter to provide greater access to the power box. Refer to FRP 37 for removal instructions. 4. Remove the cover from the power box by using the following steps: a. Use a #2 Phillips screwdriver to remove the screws that hold the cover in place. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 165 9. If necessary, remove the jumpers from the back of the old switch and install them in the same positions on the replacement switch. Figure 74. Voltage Selector Switch Location Voltage Cabinet Rear Selector (module insertion side) Switch Cabinet Front (power supply insertion side) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 166 For terminals that connect to two wires, install wires as shown Figure Figure 75. Two-wire Connection Step 3 For Terminals with 2 Wires Terminal Screw Do This Wire Do Not Do This Note: For clarity the wire clamp is not shown. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 167 7. Replace the power box cover. 8. Close the front door of the cabinet. 9. Return the cabinet to operation. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 168: Frp 33: Time-Delay Relay Replacement

    3. Remove the air filter to provide greater access to the power box. Refer to FRP 37 for removal instructions. 4. Remove the cover from the power box: a. Use a #2 Phillips screwdriver to remove the screws that hold the cover in place. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 169 3. Connect the wires to the relay. Refer to your notes for the correct locations. 4. Replace the power box cover and the air filter. 5. Restore the cabinet to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 170: Frp 34: Line Filter (Fl1) Replacement

    3. Remove the air filter to provide greater access to the power box. Refer to FRP 37 for removal instructions. 4. Remove the cover from the power box: a. Use a #2 Phillips screwdriver to remove the screws that hold the cover in place. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 171 The line filter is heavy and difficult to reach; remove it carefully. Support and protect your back when you lift the line filter. Figure 77. Line Filter Location Cabinet Rear Line Filter (module insertion side) Cabinet Front (power supply insertion side) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 172 Double-check the wiring. Ensure that none of the ring-tongue terminals touch adjacent terminals or wires. 3. Replace the power box cover and the air filter. 4. Restore the cabinet to operation and close the front cabinet door. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 173: Frp 35: Contactor (Ct1) Replacement

    3. Remove the air filter to provide greater access to the power box. Refer to FRP 37 for removal instructions. 4. Remove the cover from the power box: a. Use a #2 Phillips screwdriver to remove the screws that hold the cover in place. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 174 8. Remove the wires with a medium flatblade screwdriver. Figure 78. Contactor Location Cabinet Rear (module insertion side) Contactor Cabinet Front (power supply insertion side) Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 175 3. Connect the wires to the front (power supply side) of the contactor. Refer to your notes for the correct locations. 4. Replace the power box cover and the air filter. 5. Restore the system to operation and close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 176: Frp 36: Resistor (R1) Replacement

    Place a lockout device over the cabinet’s plug and lock/tag it. WARNING Ensure that the electrical plug for the equipment that you service is unplugged, locked, and tagged. Failure to do so could result in severe shock and burns. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 177 6. Use a #1 Phillips screwdriver to remove the 2 screws that secure R1 to the side of the power box. Figure 79. Resistor Location Cabinet Rear Resistor (module insertion side) Cabinet Front (power supply insertion side) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 178 Place the heat shrink over the solder sleeve and shrink the heat shrink. 3. Replace the power box cover. 4. Restore the cabinet to operation and ensure that the resistor operates correctly. (In other words, ensure that the contactor closes properly.) Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 179: Frp 37: Air Filter Replacement

    3. Rotate the filter bracket 90˚ toward the center of the cabinet. Refer to Figure 4. Repeat Step 2 Step 3 for the other bracket. With the brackets in the new position, the filter should drop down approximately 1.5 inches (4 cm). HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 180 filter out before you insert the replacement filter. 8. Rotate the filter brackets into the operating position, and secure them with the retaining screws. 9. Close the front cabinet door. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 181 AC Repair and Adjustment Procedures FRP 37: Air Filter Replacement Figure 81. Filter Replacement Step 6 New Filter Old Filter HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 182: Frp 38: Blower Assembly Replacement

    You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the rear cabinet door. 4. Use a small flatblade screwdriver to disconnect the clock cable connector from the clock switch board. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 183 (If the extension is not long enough to enable you to reach the nut, tilt the hex driver at a horizontal angle.) Note that the wedges are part of the blower assembly and will not fall off. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 184 AC Repair and Adjustment Procedures Figure 82. Blower Assembly and Mounting Hardware Bottom View Thumb Screws Wedge System (under mounting hardware) See Top View Figure Blower Connector Slide Rails (blower assembly slides on these rails) Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 185 Remove the blower carefully. Ensure that a second person is available to help you remove the blower. It is heavy and may cause back injury, or it may cause injury if it falls on someone. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 186 4. Replace the blower exhaust shield and the clock switch cable. 5. Power up the cabinet and check blower operation (ensure that the blower runs normally, draws a substantial volume of air through the cabinet, and maintains normal cabinet temperatures). 6. Close both cabinet doors. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 187: Frp 39: Blower Controller (Scr1) Replacement

    You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the blower circuit breaker (CB8). 4. Access SCR1: a. Open the WACS panel. b. Remove the panel that covers the blower controller (SCR1). Refer to Figure HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 188 Remove the power terminals from SCR1: a. Use a #2 Phillips screwdriver to remove the 4 screws that secure the power terminals to SCR1. (Refer to Figure 86.) b. Pull the power terminals away from SCR1. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 189 2 right screws. Slide SCR1 to the right until it clears the screws and remove SCR1 from the cabinet. Figure 85. Removing the Power Wires from SCR1 Pluggable Connections Power Connection Screws (Lugs) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 190 4. Return the cabinet to operation, and check blower function. 5. Remove power from the cabinet again, then replace the panel that covers the blower controller (SCR1). 6. Close the WACS panel, then return the cabinet to operation. 7. Close the front cabinet door. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 191: Frp 40: Transformer (T1) Replacement

    Failure to do so could result in severe shock and burns. You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the blower circuit breaker (CB8). HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 192 NOTE: It may be necessary to loosen or remove the blower controller (SCR1) to provide access to the screw on the far side of the transformer. Refer to FRP 39 for removal instructions. Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 193 3. Return the cabinet to operation, and check blower function. 4. Remove power from the cabinet again, then replace the panel that covers the blower controller (SCR1). 5. Close the WACS panel, then return the cabinet to operation. 6. Close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...

  • Page 194: Frp 41: Run Capacitor (C1) Replacement

    Failure to do so could result in severe shock and burns. You may also open, lock, and tag the customer’s wall breaker(s). 3. Open the blower circuit breaker (CB8). Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 195 6. Use the 13-mm wrench to remove the nut that secures the run capacitor. Then remove the capacitor. Figure 88. Run Capacitor (C1) Capacitor Panel Wires to C1 Wire splices are not visible. They are located toward floor.) Retaining Nut (Located on bottom of capacitor.) HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 196 3. Return the cabinet to operation, and check blower function. 4. Remove power from the cabinet again, then replace the panel that covers the blower controller (SCR1). 5. Close the WACS panel, then return the cabinet to operation. 6. Close the front cabinet door. Cray Research/Silicon Graphics Proprietary HMM-168-A...

  • Page 197: Preventive Maintenance And Adjustment Procedures

    CL (current limit) LED indicator: To reduce the output voltage, turn the screw counterclockwise slightly. To increase the output voltage, turn the screw clockwise slightly. 3. Close the front cabinet door. HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 198 FRP 41: Run Capacitor (C1) Replacement AC Repair and Adjustment Procedures Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 199 AC Repair and Adjustment Procedures FRP 41: Run Capacitor (C1) Replacement HMM-168-A Cray Research/Silicon Graphics Proprietary...
  • Page 200 FRP 41: Run Capacitor (C1) Replacement AC Repair and Adjustment Procedures Cray Research/Silicon Graphics Proprietary HMM-168-A...
  • Page 201 71 torus replacement, 65 WACS replacement, 99 Capacitor replacement, 194 CB1 replacement, 152 Circuit breaker replacement main (CB1), 152 power supply, 160 WACS panel, 156 Clock auxiliary power supply replacement, 29 bottom rail replacement, 59 Cray Research/Silicon Graphics Proprietary...
  • Page 202 120 EPROM replacement, 109 ESD precautions, 4 Filter AC line, replacement, 170 cleaning, 197 replacement, 179 EMI, cleaning, 197 FRU list, 5 FRU procedures. See Procedures Fuse replacement blower, 150 power supply, 148 WACS, 145 Cray Research/Silicon Graphics Proprietary...
  • Page 203 FRUs, 5 spares, 8 tool kit, 9 PM procedures, 197 Power See also Power cord; Power supplies circuit breaker replacement, 160 fuse replacement, 148 Power supplies auxiliary clock, replacement, 29 module, replacement, 21 rail replacement, 49 Cray Research/Silicon Graphics Proprietary...
  • Page 204 21 preventive maintenance, 197 rail replacement module, bottom, 59 module, top, 52 power supply, 49 resistor replacement, 176 run capacitor replacement, 194 SCR1 replacement, 187 switch replacement blower bypass, 122 cabinet power, 124 clock, 126 Cray Research/Silicon Graphics Proprietary...
  • Page 205 Safety information, 4 Scanner replacement, 113 SCR1 replacement, 187 Skin (trim) removal, 16 Spares list, 8 SW1 replacement, 164 Switches replacement blower controller bypass, 122 cabinet power, 124 clock, 126 voltage selector switch (SW1), 164 WACS, 120 Cray Research/Silicon Graphics Proprietary...
  • Page 206 Voltage selector switch (SW1) replacement, 164 WACS board replacement, 113 cable replacement, 99 display replacement, 117 EPROM replacement, 109 fuse replacement, 145 switch replacement, 120 thermistor replacement inlet air, 132 module, 129 outlet air, 136 thermostat replacement, 141 Cray Research/Silicon Graphics Proprietary...

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