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Qualstar TLS-4000 Technical & Service Manual

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The Tape Library Experts
TM
TLS-4000
Technical
Service Manual
501380 Rev. B

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Summary of Contents for Qualstar TLS-4000

  • Page 1 The Tape Library Experts TLS-4000 Technical Service Manual 501380 Rev. B...
  • Page 2 This manual was revised to correspond with the firmware ver- sion indicated below. Do not use this manual with different part numbers or prior ver- sions of the firmware. Check with Qualstar Technical Support about use of this man- ual with newer firmware.
  • Page 3 Technical Support Information The best source for service-related information is your system reseller. Alternately, the Qualstar Technical Support Department can be reached Monday through Friday, between the hours of 7:30 A.M. and 4:30 P.M. Pacific Time, at: Qualstar Corporation...

  • Page 4: Table Of Contents

    Table of Contents Introduction........................1-1 Who Should Read This Manual................... 1-1 Important Safety Information ..................1-2 Lithium Battery......................1-3 Description and Theory of Operation ..............2-1 Model Identification ..................... 2-1 General Description ..................... 2-2 2.2.1 Motion Systems ..................... 2-2 2.2.2 Sensors ........................
  • Page 5 Maintenance Menu....................... 4-2 4.1.1 SN ........................... 4-2 Maintenance\Display Log Menu ................4-3 4.2.1 Introduction ......................4-3 4.2.2 Data Logging – General Description..............4-4 Maintenance\Display Log\Display\Entry Menu ............. 4-5 Maintenance\Display\Prevents Status Screen............4-6 Maintenance\Display Revision Status Screen ............4-6 Maintenance\Display Stats. Status Screen ............... 4-7 Maintenance\Display Voltage Status Screen ............
  • Page 6 Operation Failures ..................... 6-10 Calibration Failures ....................6-14 Field–Replaceable Units (FRUs)................7-1 Introduction ........................7-1 Field-Replaceable Units (FRUs).................. 7-2 Required Tools and Materials ..................7-3 Top and Side Panels ..................... 7-4 Carriage Assembly ....................... 7-6 Carriage PCBA ......................7-16 Barcode Reader......................7-18 Air Filter and Fan Assembly ..................
  • Page 7 Introduction ........................9-1 Model Expansions......................9-2 9.2.1 Installing a Model Expansion Kit ................ 9-2 9.2.2 Entering the Update Password ................9-10 9.2.3 Reconfiguring the Model Number ..............9-11 9.2.4 Recalibrating the Unit ..................9-12 9.2.5 Clearing the Password ..................9-12 Barcode Reader......................

  • Page 8: Introduction

    (FRU's). It also contains troubleshooting procedures, instructions for removing and replacing FRU's and after–maintenance testing procedures. Finally, Chapter 9 con- tains the System Interconnect diagram. The following topics are covered in the TLS-4000 Installation and Operation manual (Qualstar document number 501370): •...

  • Page 9: Important Safety Information

    All of the operating instructions and maintenance procedures in Qualstar manuals must be followed to prevent personal injury or damage to the equipment. In the inter- ests of safety, there are two kinds of warnings used in Qualstar documents, as shown below.

  • Page 10: Lithium Battery

    In addition, useful information and tips may be found throughout the document in the following formats: NOTE SPECIAL ATTENTION to explanatory statements found in a NOTE paragraph will help you avoid mistakes and/or save time. NOTICE A NOTICE box contains additional important information. 1.3 Lithium Battery Please observe the following information when repairing the unit.

  • Page 11: Description And Theory Of Operation

    2. Description and Theory of Operation 2.1 Model Identification 4210, 4212, 4222 4420, 4440, 4480 4660, 46120 Figure 2-1 TLS-4000 Models TLS-4000 Feature/Model 4210 4212 4222 4420 4440 4480 4660 46120 Maximum number of tape drives Media capacity in cartridges...

  • Page 12: General Description

    Figure 2-4 TLS-4000 Dimensions 2.2 General Description Each TLS-4000 cabinet contains a high-performance robotics system for handling data cartridges, a drive bay to accommodate the cartridge tape drives, at least one car- tridge magazine, power supplies and printed circuit board assemblies (PCBAs) that contain the TLS electronics.

  • Page 13: Sensors

    • The I/O port slot extends to receive or deliver a cartridge and then re- tracts. The I/O port slot's leadscrew is driven by a DC stepper motor. • A large gear at the bottom of the Carousel Assembly is turned by a pinion gear on a DC stepper motor.
  • Page 14 3. When inserting and removing cartridges, the Y–Clear sensor is used in conjunc- tion with the Cartridge Presence sensor to check the position of a cartridge in the Handler's Gripper assembly. • Cartridge Presence Sensor This sensor, which is mounted on the handler, detects the presence of a tape cartridge in any storage location, including a tape drive (cartridge must be in ejected position).

  • Page 15: Handler Solenoid

    2.2.5 Barcode Labels Pre-printed barcode labels, which are both human- and machine-readable, are avail- able from a number of sources including Qualstar. Barcode labels must conform to ANSI/AIM BCI-1995, Uniform Symbology Specifica- tion Code 39. Please refer to PIN-040 www.qualstar.com...

  • Page 16: Component Identification

    quest. When the changer moves a cartridge, the inventory database is updated to re- flect the change. If the changers’ inventory becomes invalid (e.g. if the Inventory Sentry Beam is vio- lated), the changer rescans the inventory. The updated barcode label and cartridge position data is then stored in the inventory database.

  • Page 17: Tls Models

    2.4.1 TLS Models Figure 2-5 and Figure 2-6 show the location of the major components in both types of libraries: carousel and fixed-magazine models. Spring Cup Assy. and Plastic Washer Handler Power Supply Y-Clear Detectors I/O Port Assy. Control Panel Executive PCBA Rear Guide Shaft Cartridge Magazine...
  • Page 18 Spring Cup Assy. and Plastic Washer Handler Power Supply I/O Port Assy. Control Panel Carousel Y-Clear Detectors Carriage, Handler, Gripper Executive PCBA and Barcode Reader Front Guide Shaft Carousel Motor Vertical (Y) Axis Lead Screw Rear Guide Shaft Power Switch Carousel PCBA Cooling Fans Tape Drives...

  • Page 19: Handler

    2.4.3 I/O Port Assembly Figure 2-8 shows the major components of the TLS I/O Port Assembly. The CALL switch is mounted to the front panel and connects to the I/O port PCBA. All TLS-4000 models use the same type of I/O Port Assembly.

  • Page 20: Field-Replaceable Units (Frus)

    2.4.4 Field-Replaceable Units (FRUs) Many of the library's major components are available separately as Field-Replaceable Units (FRUs). These components can be removed and replaced in the field by qualified personnel. See Chapter 7 for a complete list of FRUs, their part numbers and re- moval/replacement instructions.

  • Page 21: The Menu System

    This chapter explains the menu system, the types of information it presents, and how to use it. Specific information about Configuration or Operation menu items can be found in the TLS-4000 Installation and Operation Manual (Qualstar document num- ber 501370).

  • Page 22: The Enter Control Key

    • If a value is highlighted, the (UP) and (DOWN) keys change the value of the highlighted character or word. The DOWN key changes the charac- ter to the preceding character in the sequence (i.e., from B to A, or from 2 to 1).

  • Page 23: The Exit Control Key

    3.1.4 The EXIT Control Key The EXIT key behaves as follows: While editing a menu item’s value, pressing the EXIT key exits the editor and restores the pointer to the menu item. Note that all values changed during editing are actually changed, exiting does not undo those changes.
  • Page 24 • When the optical sensors detect a fully-inserted tape cartridge, the I/O port slot retracts, closing the I/O port door. • If the tape cartridge is not fully inserted, the door will remain open. • If no tape is inserted, the I/O port slot retracts one or two minutes af- ter the I/O port is summoned.

  • Page 25: The Top Menu

    3.2 The Top Menu To see the Top Menu, turn on the TLS, wait until it displays the date and time, then press the MENU key. The operator should see a display like the one in Figure 3-4. Display line one always indicates the title (or its abbreviation) of the current menu or function.

  • Page 26: Menu Elements

    3.3 Menu Elements 3.3.1 Menu Items Line 1 of any menu display always indicates the name of the menu, with the exception of the Top Menu, where menu names are right justified. If space permits, the name of, or an acronym for, the parent menu will precede the menu name. The parent menu name (if it is displayed) is left justified.

  • Page 27: Values

    There is no roll-over between digits. (See Table 3-4) Example: Qualstar TLS-4210 3.3.2.3 Multiple Choice Values Each multiple choice value has its own list of valid choices. These values are not edit- able.

  • Page 28: Location Designators

    3.3.3 Location Designators A Location Designator contains six characters used to describe any physical location. A “ ” in the first character signifies a physical location and then the five remaining characters are defined below. When a character is not required to define a par- ticular location, the character is replaced with a decimal point or dot.
  • Page 29 or a cartridge location. If the cursor appears over the entire value, it is a multiple- choice value. 3.3.4.1 Editing Multiple-Choice Values If the item contains a multiple-choice value, the entire value will be overlaid with flashing block cursors. Use the (UP) key to select the next value and the (DOWN) key to select the previous value, then press EXIT when done.
  • Page 30 I/O Slot Private Slot Tape Drive Locations Refer to Chapter 3 in the TLS-4000 Installation and Operation Manual (Qualstar document number 501370) for the ranges of location values and their physical loca- tions. To select a different designator, place the cursor on the letter and use the (UP) or (DOWN) key to select a different letter.

  • Page 31: The Menu Hierarchy

    Once the configuration parameters have been correctly set for a given in- stallation, they are not changed unless something in the system's configuration is changed. The functions available under the Configuration menu are fully explained in the TLS-4000 Installation and Operation Manual (Qualstar document number 501370). NOTE Be aware that the configuration parameters may also be set by the SCSI interface.

  • Page 32: Displaying The Tls Firmware Revision

    3.5 Displaying the TLS Firmware Revision The revision of the changer’s firmware may be displayed by using the Maintenance menu. Press the MENU key to display the . Press the (DOWN) key until Top Menu the arrow on the left side of the display points to , then press the EN- MAINTENANCE TER key.

  • Page 33: Maintenance Menu

    Maintenance Menu The Maintenance menu is used to display detailed information about the TLS and its operating history, and to test the functionality of the liquid crystal display and menu control keys. The Maintenance menu is available to the system user and is considered safe.

  • Page 34: Maintenance Menu

    NOTE The menus in this chapter reflect revision 2.21 of the Executive PCBA EPROM software. If an ear- lier revision of the software is being used, some menu items may not appear in the menus. 4.1 Maintenance Menu ..Maintenance .

  • Page 35: Maintenance\Display Log Menu

    SCSI interface or Handler operation problems. The logging system is most effectively used by a field service person who is working under the direction of a Qualstar Technical Support technician. First, the field service person reports a problem's symptom(s) to a Qualstar Technical Support technician, then the technician directs the field service person to look only at problem-specific logged data.

  • Page 36: Data Logging - General Description

    Refer to the Configuration\Advanced\Log sec- tion in the TLS-4000 Installation and Operation Manual (Qualstar document number 501370) for details.

  • Page 37: Maintenance\Display Log\Display\Entry Menu

    Refer to the Configuration\Advanced\Log section in the TLS-4000 Installation and Operation Manual (Qualstar document number 501370) for details. Maintenance Menu...

  • Page 38: Maintenance\Display\Prevents Status Screen

    The user can also use the Display Log\Entry menu to turn the data display class masks on or off, as the user can do with the Display Log menu. The difference here is that logging activity is suspended when the user enters Display Status screen, and remains suspended while the Display Log\Entry menu is displayed.

  • Page 39: Maintenance\Display Stats. Status Screen

    • Checksum: This is the checksum value of the current firmware. (It takes a second to calcu- late this value). 4.6 Maintenance\Display Stats. Status Screen M ..Display Stats. Aborts: dddddddddd DoorOpn:dddddddddd Exchang:dddddddddd Filter: dddddddddd Grips: dddddddddd I Calls:dddddddddd I Moves:dddddddddd I Steps:dddddddddd Minutes:dddddddddd Moves:...
  • Page 40 • I Moves This value is the number of times that the I/O port slot has moved. (The I/O port slot's extend/retract cycle counts as two moves.) • I Steps This value is the number of I/O port stepper motor steps (200/revolution, 800/inch).

  • Page 41: Maintenance\Display Voltage Status Screen

    4.7 Maintenance\Display Voltage Status Screen M ..Display Voltage +3.3V: dd.ddd +5V: dd.ddd +12V: dd.ddd The Display Voltage status screen displays the current Handler power supply volt- ages. The +12V supply is the voltage coming into the Executive PCBA from the Han- dler power supply.

  • Page 42: Maintenance\Test Keyboard Status Screen

    4.9 Maintenance\Test Keyboard Status Screen M ..Test Keyboard ENTER & EXIT to exit ddddd The Test Keyboard status screen provides a direct indication of menu control key functionality. Whenever a key is pressed, its 2-character abbreviation appears on the screen (Up, Ex, Re, Do, En, Me).

  • Page 43: Maintenance\Test Lc Display Status Screen

    4.10 Maintenance\Test LC Display Status Screen The TLS uses a four-line Liquid Crystal Display that displays 20 characters per line. This status screen uses three different test screens to check the operation of the dis- play. After selecting the Maintenance\Test LC Display screen, use either the (UP) (DOWN) key to select any one of the three test screens.

  • Page 44: The Private Menu

    The Private Menu ..... Private Access: ?????????? . Calibration CALIBRATE . Carousel CLEAR ACCESS . Configuration . Display A/D LEGEND . Display Locations . Display Positions = cartridge location . Display Sensors = decimal number . DriveBay = hexadecimal number Executive = alphanumeric character RESET SCSI BUS...

  • Page 45: Introduction

    Continued from Figure 5-1 P .. Display Positions P ..Display Sensors Private ..DriveBay . Bay ddddd !Adapt: . EEPROM ddddd ISHome: ddddd Locked: Period Y: ddddd !Open: ddddd !ScsiDF: Private . DriveBay . Bay P . DriveBay ..EEPROM Period Z: ddddd !Shunt1:...

  • Page 46: Security Locks

    TLS for remote operation only. 5.2.3 Disabling the Master Security Lock NOTE See the TLS-4000 Installation and Operation Manual (Qualstar document number 501370) for details about the TLS Security options. Follow the instructions below, which assume that all TLS security locks are set to to disable the security lock.

  • Page 47: Enabling The Private Menu

    Top Menu •Configuration •Maintenance •Operation Press the ENTER key once to enter the menu. \Configuration •••••••Configuration •Advanced •Drive SCSI ID: •Security SET TO DEFAULTS Use the (DOWN) key to move the pointer to Security Press the ENTER key to enter the menu.

  • Page 48: Setting A Password

    • Service is the password used by qualified service personnel to access cer- tain menu items while servicing the TLS. Please note that only \Private the first letter is capitalized. • Update is the password used by qualified service personnel to access other menu items while upgrading a TLS, adding or removing a Bar- \Private code Reader, or replacing the Executive PCBA.
  • Page 49 •••••••••Maintenance •Display Log •Display Prevents •Display Reservs. •Display Revision •Display Sense •Display Stats. •Display Voltage •Test Inventory •Test Keyboard •Test LC Display Use the (DOWN) key to move the pointer to Test LC Display Press the ENTER key to enter the menu.

  • Page 50: Clearing The Password

    Press the (UP) or (DOWN) key repeatedly to select the desired character (be sure to use the correct capital and lower-case letters), then press the ENTER key once to shift the flashing cursor to the next character position. Repeat step 12 to finish entering the password. Press the MENU key repeatedly to leave the menu system and set the password.

  • Page 51: Private\Calibrate Command

    5.4 The Private Menu 5.4.1 Private\CALIBRATE Command command should not be executed without a specific reason for doing CALIBRATE so, because it involves risk. For example, if the command is used incor- CALIBRATE rectly, improper Handler operation may result. Therefore, if the Handler is properly picking and placing cartridges, and the user does not have a specific reason for using command, recalibrating the TLS is not recommended.

  • Page 52: Private\Clear Access Command

    CAUTION If the TLS is not properly set up prior to invoking the CALIBRATE command, the calibration process can result in invalid calibration data, which may prevent Han- dler operation. Using the CALIBRATE Command Press the MENU key to open the Top Menu. Use the (DOWN) key to move the pointer in the left column to Private, then press the ENTER key to open the Private menu.

  • Page 53: The Private\Calibration Data Status Screen

    The Calibration Data Status screen displays the calibration data determined by the CALIBRATION command. If, for example, the user encounters some particularly dif- ficult Handler problem, it may become necessary to relay the data on this screen to a Qualstar Technical Support technician. 5-10 The Private Menu...
  • Page 54 This value is the threshold for the Inventory Sentry Beam's optical detector. (This sensor is also known as the Y-Clear Sensor). • YCLEARM This item appears in the menu, but it is not used for TLS-4000 libraries. • Y DATA 0 This value is the location of the top tape drive.

  • Page 55: The Private\Carousel Menu

    5.4.5 The Private\Carousel Menu Private ..Carousel Current Stop: Demand Stop: ABORT SLEW SLEW Current Pos:±ddddd Index: BLOCKED STEP DOWN STEP UP The Carousel menu allows the user to completely control the Carousel and to display the Carousel's current position. NOTE Carousel is a model-dependent item.
  • Page 56 Face Number on Model: STOP 4222 4440 4480 4660 46120 Nominal Position 2888 2667 2400 2133 1600 1067 Table 5-1 Carousel Rotation Information The Carousel menu contains the following values: • Current Stop This value is the current Stop number (Table 5-1) A value of 255 indicates that the carousel is between Stops, or that the Carousel has been bumped off of a Stop.

  • Page 57: The Private\Configuration Menu

    Example 1: The default text used on line 1 of the main display for a TLS-4210 is . However, an operator can enter custom data (e.g., different Qualstar TLS-4210 text) for the main display line 1 over the SCSI bus, or by using the menu.

  • Page 58: The Private\Configuration\Scsi Menu

    • SCSI Vndr Allows for vendors or resellers name to be entered which will replace the sys- tem’s default menu display text ( Qualstar • SCSI Prod Allows for vendors or resellers product name to be entered which will replace the system’s default menu display text (...

  • Page 59: The Private\Display A/D Status Screen

    5.4.9 The Private\Display A/D Status Screen Private .. Display A/D +12V ddddd +3.3V ddddd ddddd CARSPR: ddddd CRTPRS: ddddd I/O CLEAR: ddddd I/O FULL: ddddd Internal 0: ddddd Internal Mid:ddddd InternalFull:ddddd TPWR: ddddd YCLEAR: ddddd YCLEARM: ddddd The Display A/D Status screen displays the current analog to digital converter output values.

  • Page 60: The Private\Display Locations Menu

    Table 5-2 A/D Converter Inputs 5.4.10 The Private\Display Locations Menu P .. Display Locations Location: llllll Accessable: FALSE Access.Valid:FALSE Barcodeable: FALSE Label: ?????????? Label Error: FALSE Label Valid: FALSE Occupied: FALSE Occup.Valid: FALSE On My Side: FALSE Present: FALSE Pres. Valid: FALSE Source Valid:FALSE Source Loc.:llllll Synchronized:FALSE...
  • Page 61 Data The Source value indicates the prior location of the cartridge that is currently at the selected location. The Item value is an internal number. It is useful only to a Qualstar Technical Support technician. Synchronized TRUE/FALSE When an inventory item is modified on one side of the library, the data is first only in the corresponding sides Executive PCBA.

  • Page 62: The Private\Display Positions Status Screen

    5.4.11 The Private\Display Positions Status Screen P .. Display Positions ±ddddd ±ddddd ±ddddd PeriodY: ddddd ±ddddd PeriodZ: ddddd The Display Positions status screen displays the current position of the four motor- driven positioners. The positions are given in motor steps, counted from the home po- sition of each axis.

  • Page 63: The Private\Display Sensors Status Screen

    5.4.12 The Private\Display Sensors Status Screen P ..Display Sensors !Adapt: ISHome: Locked: !Open: !ScsiDF: !Shunt1: !Shunt2: XIndex: YHome: ZHome: The Display Sensors Status screen displays the current logical state (1 or 0) of the various control inputs. • !Adapt A 0 indicates that a adapter is installed on the Executive PCBA.

  • Page 64: The Private\Drivebay Menu

    5.4.13 The Private\DriveBay Menu Private ..DriveBay . Bay . EEPROM menus show the status of the Drive Bay circuit board and Private\DriveBay the EEPROM on the circuit board. The meaning of the EEPROM data is beyond the scope of this document. 5.4.13.1 The Private\DriveBay\Bay Menu Private .

  • Page 65: The Private\Executive Menu

    5.4.14 The Private\Executive Menu Private ..Executive Firmware: ?????? I2C Address: PCB Number: 501??7 PCB Revision: • Firmware Indicates the current revision of the Executive firmware. • I2C Address The address of the Executive PCBA on the I C bus. •...

  • Page 66: Troubleshooting

    Troubleshooting After a Tape Library System (TLS) is serviced in the field, there are three types of failures that might occur when power is reapplied: Power Up and Initialization, Op- eration, or Calibration. This chapter lists the possible failures that might occur in each category and also the possible causes for each type of problem.
  • Page 67 The alerts Carousel Jammed appears on the control panel display. Also, the Carousel motor makes a loud noise and does not turn, or the carousel turns, then stops and makes a loud noise.................6.1.15 The Carousel turns for awhile, then the alert XHome Fail appears on the control panel display......................6.1.16 The alert ZHome Fail appears on the control panel display, and the Insertion Axis is all the way back (nearest the cabinet door)............6.1.17...

  • Page 68: Power Up And Initialization Failures

    6.1 Power Up and Initialization Failures When the library's power is first turned on, it does a Power-On Sequence Test and then scans the inventory. The errors in this section occur during the power- on/inventory-taking process. 6.1.1 When the power is turned on, no motion occurs, the control panel display does not light up and the machine makes a regular, clicking sound.

  • Page 69: The Control Panel Display Lights Up And Shows Text, No Errors Are Displayed, But Nothing Moves

    The firmware on the Executive PCBA was destroyed because the power was in- terrupted while uploading new code. If this happens, you must replace the execu- tive PCBA, or replace the DIP Flash-Memory chip on the Executive PCBA. 6.1.4 When the power is turned on, the control panel display lights up and shows text, no errors are displayed, but nothing moves.

  • Page 70: The Alert Bcr Failure Appears In The Control Panel Display

    The LCD display has failed. 6.1.8 When the power is turned on, the alert Bcr Failure appears in the control panel display. On power up, the library attempts to communicate with the bar code reader module. If the library is configured for a bar code reader, but this communication fails, this er- ror results.
  • Page 71 The Vertical Axis Home Sensor has failed. The Carriage cable is damaged, or not properly connected. The Vertical Axis Home Sensor Probe (see Figure 2-5) is missing or damaged. The Vertical Axis motor is not properly connected. The Vertical Axis motor has failed. 6.1.11 When the power is turned on, the alert Ioport Jammed appears on the control panel display, and you do not hear a whining sound for several seconds before the alert occurs.
  • Page 72 The Shaft Coupling between the I/O port motor and the leadscrew is not clamped properly. This case makes a quieter buzzing sound than the others. 6.1.13 When the power is turned on, the message Needs Calibration ap- pears on the control panel display. Possible cause: The unit needs to be calibrated, due to an Executive PCBA replacement, Configura- tion change, or a failed calibration attempt.

  • Page 73: The Alert Zhome Fail Appears On The Control Panel Display, And The Insertion Axis Is All The Way Back (Nearest The Cabinet Door)

    The Carousel is jammed, or binding and does not turn freely, generally caused by a cartridge not fully inserted in a magazine or storage slot. Also may be caused by a magazine not properly installed on its mount. The Cable from the Executive PCBA to the Carousel PCBA is damaged, or not properly seated.

  • Page 74: The Alert Zhome Fail Appears On The Control Panel Display, And The Insertion Axis Is Not All The Way Back (Nearest The Cabinet Door)

    6.1.18 When the power is turned on, the alert ZHome Fail appears on the control panel display, and the Insertion Axis is not all the way back (nearest the cabinet door). When the power is turned on, the library attempts to drive the gripper (Z axis) all the way toward the door, then verifies that the Z home sensor detects the gripper assem- bly.

  • Page 75: Operation Failures

    6.2 Operation Failures The problems in this section occur during normal operation. 6.2.1 During operation, a key on the key pad works intermittently, or completely fails to operate. Possible cause: A switch on the Control Panel PCBA has failed. It is possible to pry the cap off the switch and clean the contacts.

  • Page 76: The Barcode Reader Does Not Read Bar Code Labels Reliably

    The bar code reader has failed. The barcode labels are dirty or damaged. 6.2.4 The Barcode Reader does not read bar code labels reliably. The library uses the Code 3 of 9 (also know as code 39) barcode format for the car- tridge labels.

  • Page 77: The Alert Cart Jammed Appears On The Control Panel Display, And There Is No Cartridge In The Handler's Gripper

    The Seq.Labels value in the Configuration\Advanced\Changer\Inventory menu is set to ALL, and some of the sequential cartridges do not have bar code labels. Change the Seq.Labels value to SOME, or put bar code labels on all of the se- quential cartridges. 6.2.6 During operation, the alert Cart Jammed appears on the control panel display, and there is no cartridge in the Handler's gripper.

  • Page 78: The Alert Handler Jammed Appears On The Control Panel Display

    The library is configured for the wrong TLS model. If the location is a tape drive, the drive is configured to the wrong type. The calibration data is corrupt and the library needs to be recalibrated. The Insertion Axis is binding near the magazine end of its travel. 6.2.8 During operation, the alert Handler Jammed appears on the control panel display.

  • Page 79: Calibration Failures

    6.2.10 During operation, the alert Not Clear appears on the control panel display. This indicates that the Sentry Beam (also known as the “Y Clear”) is unexpectedly ob- structed. The Sentry beam is an invisible light beam, which travels from an emitter at the bottom of the library to a sensor at the top, between the carriage and the car- tridges.

  • Page 80: The Alert Yclear Fail Appears On The Control Panel Display

    IMPORTANT: Refer to section 6.1 (Power Up and Initialization Failures) for problems not listed in this section. 6.3.1 During Calibration, the alert YClear Fail appears on the control panel display. The calibration sequence blocks and unblocks the path of the Y clear light beam, and reads the sensor output level to determine proper operation, and to calculate a threshold for detecting a blocked condition.

  • Page 81: The Alert Iclear Sensor Fail Appears On The Control Panel Display

    threshold for detecting a blocked condition. This fault indicates that the sensor or emitter is not functioning correctly. Possible causes: The Cartridge Presence Sensor's emitter or detector is not properly connected. There are small connectors on the PCBA on the bottom of the carriage that carry the signals to the emitter and detector.

  • Page 82: The Alert Calibration Failed Appears On The Control Panel Display

    The I/O port PCBA has failed. 6.3.5 During Calibration, the alert Calibration Failed appears on the control panel display. During calibration, the library “feels” for the height of some of the storage slots to compensate for mechanical variations. This fault indicates that the library was un- able to calibrate one of the slots.

  • Page 83: Field-Replaceable Units (Frus)

    BZW. SEITENPLATTE ENTFERNT SIND. 7.1 Introduction Many of the major components in the TLS are available from Qualstar as separate Field-Replaceable Units (FRUs). Each FRU can be removed and replaced on-site by qualified personnel. Some of the FRUs are mechanical assemblies while others are Printed Circuit Board Assemblies (PCBAs) or Integrated Circuits.

  • Page 84: Field-Replaceable Units (Frus)

    7.2 Field-Replaceable Units (FRUs) Table 7-1 lists all of the FRUs available from Qualstar for the TLS-4000 libraries. Field Replaceable Unit Time Description FRU Part Number Section Page Min. Carriage Assembly 500650-01-5 Carriage PCBA 500627-01-3 7-16 Barcode Reader Assembly 500983-01-0...

  • Page 85: Required Tools And Materials

    Diagonal Wire Cutters Table 7-2 Required Tools The materials listed in Table 7-3 may be required when replacing some FRUs. 3-inch X 3/32-inch Replacement Cable Ties Qualstar P/N 669-1001-9 Loctite 242 Instant Adhesive Leadscrew Lubricant Qualstar P/N 732-0003-2 Latex Glove...

  • Page 86: Top And Side Panels

    7.4 Top and Side Panels Tools Required: • Number 2 Phillips Screwdriver FRONT BACK FRONT Note: FRONT FRONT Larger units have several screws in this back edge. LEFT SIDE LEFT SIDE (Top Panel Removed) (Top Panel Removed) Figure 7-1 Top and Side Panels – Model 4210 7.4.1 Top Panel Removal Turn off the TLS power and remove the power cord.
  • Page 87 Reinstall the screws removed in Section 7.4.1, step 3. Reinstall the screws removed in Section 7.4.1, step 4. Close the cabinet door. 7.4.3 Side Panel Removal (Left or Right) Turn off the TLS power and remove the power cord. Open the cabinet door. Remove the Top Panel (Section 7.4.1).

  • Page 88: Carriage Assembly

    7.4.4 Side Panel Replacement (Left or Right) Turn off the TLS power and remove the power cord. Open the cabinet door. For either Side Panel, place the Side Panel (left or right side) on the TLS. If you are replacing the right Side Panel, replace the screws removed in Section 7.4.3, step 4.
  • Page 89 Y-Clear Emitter Assy. Tape Drive Power Supply Drive Bay PCBA Figure 7-3 TLS-4000 Side View – Fixed-magazine Models 7.5.1 Carriage Assembly Removal Turn off the TLS power and remove the power cord. Remove the Top Panel as described in Section 7.4.1.
  • Page 90 Carriage Cable Clamp Mounting Screws Figure 7-4 The TLS-4000 Carriage Assembly – Top View Lay the TLS on its left side (as seen from the front) to gain access to the bottom Leadscrew retaining screw (Figure 7-5). Cabinet Foot Leadscrew...
  • Page 91 Remove the Leadscrew/Spring Cup subassembly through the top plate by gently raising the Carriage Assembly all the way to the top of the Vertical (Y) Axis range of motion. NOTE In the next step, a thin metal spacer may come loose from the bottom of the Leadscrew. While holding the Carriage Assembly at the top of its vertical range of motion, rotate the Leadscrew counter-clockwise to disengage it from the Vertical (Y) Axis Leadscrew Motor/Nut (Figure 7-6).
  • Page 92 Rear Guide Shaft Bearing Carriage Cable Clamp Vertical (Y) Axis Leadscrew Motor/Nut Front Guide Shaft Bearing Insertion Axis Motor Figure 7-6 The TLS-4000 Carriage Assembly Spring Cup Assembly Enclosure Washer Robotics (Handler) Power Supply I/O Port Full/Clear Guide Shaft Strike Plate...
  • Page 93 7.5.2 Carriage Assembly Replacement This procedure assumes that the Carriage Assembly was removed in Section 7.5.1. CAUTION Recalibrate the TLS after replacing the Carriage Assembly. Be very careful not to damage the Vertical Axis Home Sensor while installing the Carriage Assembly. There is very little clearance between the sensor (underneath and to the rear of the Carriage Assembly) and the Vertical (Y) Axis Home Sensor Probe, which is mounted on the floor of the cabinet (Figure 7-3).
  • Page 94 CAUTION To prevent scratching the Leadscrew's delicate Teflon ® coating, carefully follow the instructions below. To install the Leadscrew/Spring Cup subassembly, lift the Carriage Assembly all the way up to the top of the Vertical (Y) Axis range of motion and hold it there. Insert the bottom end of the Leadscrew (Figure 7-8) into its hole in the top plate, then lower the Leadscrew down into the threaded hole in the Vertical (Y) Axis Leadscrew Motor/Nut (Figure 7-6).
  • Page 95 NOTE Make sure that the white spacer on the top end of each Guide Shaft is visible. If one of the white spacers is not visible, the corresponding Guide Shaft is upside down. Place a Guide Shaft strike plate over each of the two Guide Shaft holes on the top plate (Figure 7-7).
  • Page 96 Assembly (P/N 500650-01-5) is changed. The number of Y-Axis moves is displayed in the Maintenance\Display Stats. status screen (see Section 4.6). IMPORTANT: Use only Qualstar Leadscrew Lubricant, part number 732-0003-2, for this procedure. 7-14 Field–Replaceable Units (FRUs) 501380 Rev. B...
  • Page 97 For short Vertical (Y) Axis Leadscrews, use a single, 0.25-inch cube of Qual- star Leadscrew Lubricant. b) For tall Vertical (Y) Axis Leadscrews, use a single, 0.3-inch cube of Qualstar Leadscrew Lubricant. Apply the lubricant to the tip of your index finger, then rub your thumb and in- dex finger together to spread the lubricant evenly on your fingertips.

  • Page 98: Carriage Pcba

    7.6 Carriage PCBA P/N 500627-01-3 Tools Required: • Number 1 Phillips Screwdriver The Carriage Assembly must be removed before replacing the Carriage PCBA. Hole for Vertical (Y) Axis Home Sensor Probe PCBA Mounting Screws (4) Cable Clamps (2) CRTDET CRTEMT Cable Barcode Reader CRTDET...
  • Page 99 Unplug the two gripper solenoid wires from the GRIPA and GRIPB terminals. Use a number 1 Phillips Screwdriver to remove all four PCBA mounting screws. 7.6.2 Carriage PCBA Replacement Refer to Figure 7-10. This procedure assumes the Carriage PCBA was removed in Section 7.6.1. CAUTION After replacing the Carriage Assembly PCBA, the TLS must be recalibrated after the Carriage Assembly is reinstalled.

  • Page 100: Barcode Reader

    7.7 Barcode Reader P/N 500983-01-0 A barcode reader is optional on some TLS units and standard on others (Figure 2-2). The instructions in this section assume that a barcode reader exists in the unit, and that it will be removed and then replaced. If you are installing a new barcode reader for the first time, or permanently removing the currently-installed barcode reader, follow the instructions in Chapter 8.
  • Page 101 Gripper Assembly Barcode Reader Barcode Reader Access Hole in rear of Barcode Reader Cable Mounting Screws Insertion Axis Motor Figure 7-11 Barcode Reader (TLS-180/360 Model Shown) Refer to Figure 7-11. 7.7.1 Barcode Reader Removal NOTE It is not necessary to remove the Carriage Assembly from the TLS before removing the Barcode Reader.
  • Page 102 PROM as described in this manual or Product Information Note #012. Follow the instructions in Section 5.3.1 to enter as the password in the Update Private menu. Follow the instructions in the TLS-4000 Installation and Operation manual (Qualstar document number 501370), to edit the value in the Configura- tion\Advanced\Changer\Mechanics menu, to reflect the correct model number for the currently-installed barcode reader.

  • Page 103: Air Filter And Fan Assembly

    Follow the instructions in the menu Configuration\Advanced\Changer section in the TLS-4000 Installation and Operation manual (Qualstar dcument LabelCheckChar number 501370) edit the value in the Configura- tion\Advanced\Changer. 7.8 Air Filter and Fan Assembly Air Filter P/N 500584-01-6 42xx Fan Assembly P/N 500700-01-8...
  • Page 104 1/4-turn Fasteners Drive Access Hatch Air Filter Clamp Ground Strap Screw Drive Access Hatch Mounting Screws (3) Figure 7-12 TLS Rear View Use a flat-blade screwdriver to turn the single 1/4-turn fastener at the top of the Air Filter Clamp counter-clockwise (Figure 7-12). Open the Air Filter Clamp and lift it off of the TLS.
  • Page 105 Edge View of Air Filter Install with arrows facing into the cabinet. Figure 7-13 Air Filter - Edge View 7.8.2 Fan Assembly Removal 42xx Models Refer to Figure 7-12. Remove the Top Panel (Section 7.4.1), then remove the right Side Panel (Section 7.4.3).
  • Page 106 Lift the Line Plug Cover out of the TLS. Use a number 2 Phillips screwdriver to remove all six Rear Service Panel mount- ing screws, then remove the Rear Service Panel (Figure 7-25). Carefully cut the Cable Tie on the Executive PCBA that is attached to the Fan Assembly’s power cables.
  • Page 107 Move the bottom of the Fan Assembly toward the Drive Access Hatch opening and rotate the Fan Assembly about 90 counter-clockwise (Figure 7-16). Executive PCBA 12V Fans Connector Cable Tie Fan Assembly Drive Access Hatch Opening Rotate the Fan Assembly counter-clockwise, as seen from the rear of the TLS, to remove it.
  • Page 108 Reconnect the SCSI Cable to the Executive PCBA, then reconnect it to the tape drives (Figure 7-28). Insert the line plug cover through the Drive Access Hatch, with the mounting screw holes in the flange facing the Drive Access Hatch (Figure 7-17). Drive Access Hatch Line Plug Cover Drive Access Hatch...
  • Page 109 Reinstall the right Side Panel (Section 7.4.4), then reinstall the Top Panel (Section 7.4.2). 7.8.4 Fan Assembly Removal 44xx and 46xxx Models Remove the Top Panel (Section 7.4.1), then remove the right Side Panel (Section 7.4.3). The openings in the right side of the TLS’ frame give access to the nuts on the back of the Fan Assembly's mounting screws.
  • Page 110 7.8.5 Fan Assembly Replacement 44xx and 46xxx Models Insert the Fan Assembly into the TLS through the Drive Access Hatch and move the Fan Assembly into position in the left side of the cabinet (Figure 7-18). Align the Fan Assembly's mounting screw holes with the mounting screw holes in the TLS, then reinstall all four Fan Assembly mounting screws (Figure 7-15).

  • Page 111: I/O Port Assembly

    7.9 I/O Port Assembly P/N 500750-01-3 Tools Required: • Number 2 Phillips Screwdriver • 5/16-inch Open-end Wrench I/O Port Mounting Screws (5) Front Rear LED Cable I/O Port Cable Figure 7-19 Top View of Library 7.9.1 I/O Port Assembly Removal Turn off the TLS power and remove the power cord.
  • Page 112 Gently pull on the Call switch button to remove it (Figure 7-20). Support the I/O port assembly with one hand, then remove all five I/O port mounting screws (Figure 7-19). Gently move the I/O port assembly about one inch toward the rear of the TLS, until the Call switch clears the TLS’...

  • Page 113: I/O Port Pcba

    Gently pull on the Call switch button to remove it (Figure 2-8). Insert the I/O port assembly through the open cabinet door. Be careful not to damage the Call switch while inserting it through the hole in the TLS’ frame. Make sure that the LEDs cable is positioned in the center of the cutout in the TLS’...
  • Page 114 I/O Port Lead Screw I/O Port Axis Motor I/O Port Slot KCALL I/O Port Door Connector MOTOR Connector I/O Full: I/O Clear Sensor Emitter PCBA I/O Port Cable Plug 5 PCBA Mounting Screws Note: The LED’s Cable Plug is located underneath I/O Port PCBA the I/O Port PCBA Bottom View...

  • Page 115: Switch Bracket Assembly (Front Panel)

    Turn the I/O port assembly over and connect the LEDs cable. Note that the con- nector is keyed for correct orientation. Reinstall the I/O port assembly (Section 7.9.2). Recalibrate the TLS. (See Section 5.3.2 for details.) 7.11 Switch Bracket Assembly (Front Panel) P/N 500815-01-4 Tools Required: •...
  • Page 116 NOTE In the next step, the spacers behind the Switch Bracket Assembly come loose when the mount- ing nuts are removed. The top two spacers are shorter than the lower spacers. Remove all six mounting nuts from the Switch Bracket Assembly mounting studs using a 1/4-inch nutdriver (Figure 7-22).
  • Page 117 Position a second Nylon Cable Tie over the Switch Bracket Ribbon Cable, then attach it to both ends of the Nylon Cable Tie in the Switch Bracket Assembly (Figure 7-23). Tighten the Nylon Cable Ties, without crimping the cable, until they secure the Switch Bracket Ribbon Cable to the Switch Bracket Assembly.

  • Page 118: Handler Power Supplies

    7.12 Handler Power Supplies DANGER TO AVOID THE RISK OF PERSONAL INJURY, ALWAYS WAIT ABOUT ONE MIN- UTE AFTER THE POWER IS TURNED OFF AND THE POWER CORD IS DISCON- NECTED, BEFORE TOUCHING THE HANDLER POWER SUPPLY OR THE TAPE DRIVE POWER SUPPLY.
  • Page 119 Protective Screen Screen Mounting Screws (4) 2-Wire Cable Connector 500826-07-8 Power Cable Connector Power Supply Mounting Screws (4) Handler Power Supply Label Power Cable Power Cable Connector Connector Yellow Wires 500826-05-2 500826-13-6 Brown Wires Power Cable Connector Screws (2) 2-Wire Cable 2-Wire Cable Connector Connector...
  • Page 120 7.12.2 Handler Power Supply Replacement – 4212 and 4222 Models Insert the Power Supply into place in the side of the TLS with its connectors to- wards the rear of the TLS. Install all four Power Supply mounting screws (Figure 7-24). Reconnect the Power Cable and 2-Wire Cable connectors to the Power Supply PCBA (Figure 7-24).
  • Page 121 Rear Service Panel Mounting Screws (6) IOPORT Connector FRONT Connector Executive PCBA Figure 7-25 TLS Rear View Field–Replaceable Units (FRUs) 7-39 501380 Rev. B...
  • Page 122 Power Supply Mounting Screws (4) Protective Screen Protective Screen Mounting Screws (4) Power Cable Connector 500826-01-1 2-Wire Cable Connector Switch Bracket I/O Port Cable (FRONT) Cable Handler Power Supply Label 2-Wire Cable Power Cable Connector Connector Yellow Wires 500826-05-2 500826-10-2 Brown Wires Power Cable 2-Wire Cable...
  • Page 123 Remove all four Power Supply mounting screws (Figure 7-26). Lift the Power Supply up and out of the TLS. 7.12.4 Handler Power Supply Replacement – 4210, 44xx and 46xxx Models Lower the Power Supply down into place on top of the TLS. NOTE Make sure that the Power Supply is turned so that the Power Cable Connector on its PCBA is facing the right side of the library, as seen from the back of the TLS (Figure 7-26).

  • Page 124: Tape Drive Power Supplies

    7.13 Tape Drive Power Supplies DANGER TO AVOID THE RISK OF PERSONAL INJURY, ALWAYS WAIT ABOUT ONE MIN- UTE AFTER THE POWER IS TURNED OFF AND THE POWER CORD IS DISCON- NECTED, BEFORE TOUCHING THE HANDLER POWER SUPPLY OR THE TAPE DRIVE POWER SUPPLY.
  • Page 125 Power Supply Mounting Screws (4) 2-Wire Cable Power Cable Connector Connector 500826-02-9 Protective Screen Tape Drive Power Supply Label Mounting Screws (4) Screen Power Supply Mounting Screws (4) Screen Mounting Screws (4) Tape Drive 500826-12-8 500826-03-7 Power Supply Label Protective Power Cable Screen Connector...

  • Page 126: Executive Pcba

    Install all four Power Supply mounting screws (Figure 7-27). Reconnect the Power Cable and the 2-Wire Cable connectors to the Power Supply PCBA (Figure 7-27). Place the protective Screen on top of the Power Supply and install all four Screen mounting screws (Figure 7-27).
  • Page 127 Nut/Lockwasher TLS Frame Mounting Studs (4) Mounting Stud PCBA FRONT IOPORT POWER Spacer PCBA NO. Location Heat Sink Flange Heat Sink Flange CARAGE RS485A RS485B Heat Sink Flange Mounting Screws (4) SERLB SERLA RS485I CAROSL WADAPT OPTO LVD/SE DRVBAY PWRDST Hole for cable tie which attaches 12V FANS wires to PCBA FANS...
  • Page 128 Tools Required: • Number 2 Phillips Screwdriver • 1/4-inch Hex Nutdriver Material Required: • 3-inch x 3/32-inch Cable Ties NOTICE If a history of the configuration changes that were made at the time of initial TLS installation is not available, and if the menu system is still operational, enter the Configuration menu.
  • Page 129 If a HVD Adapter PCBA is mounted on the Executive PCBA, follow the proce- dure in Section 7.18 to remove it and mount it onto the replacement Executive PCBA (Figure 7-40). Remove all four Phillips mounting screws from the Heat Sink Flanges. NOTE In the next step, the spacers behind the Executive PCBA come loose when the PCBA mounting nuts are removed.
  • Page 130 CAUTION To prevent possible injury or equipment damage, BEFORE APPLYING POWER af- ter the Executive PCBA is replaced, MAKE SURE THE CABINETDOOR IS OPEN. When power is applied to the TLS while the cabinet door is open, no TLS motors will operate.
  • Page 131 Reinstall all four PCBA mounting nuts (with lockwashers) onto the mounting studs, then use a 1/4-inch nutdriver to tighten the mounting nuts firmly against the Executive PCBA. Reinstall all four Phillips mounting screws in the Heat Sink Flanges, then use a number 2 Phillips screwdriver to tighten the mounting screws until they are snug.
  • Page 132 • RS485A, RS485 or RS485I (Executive IV PCBA’s only) These connectors are keyed. CAUTION To avoid equipment damage, be sure that all pins on the 12VFANS cable’s plug mate correctly with all pins on the 12VFANS connector on the Executive PCBA. •...
  • Page 133 Inspect the label on the Carriage to determine its revision level (e.g., ). See Figure 7-31. Carriage: B If a Barcode Reader is installed, inspect its label to determine its model number (e.g., ). See Figure 7-31. WA3700/B-2221 Barcode Reader Barcode Reader (Rear View) Barcode Reader...
  • Page 134 Follow the instructions in Section 5.3.1 to enter for the password in the Update Private menu. Enter the menu. Configuration\Advanced\Changer\Mechanics a) Edit the menu as Configuration\Advanced\Changer\Mechanics necessary to make sure that all the menu items match the hardware installed in the TLS.

  • Page 135: Drive Bay Pcba

    7.15 Drive Bay PCBA 2–Drive P/N 501326-01-1 4–Drive P/N 501336-01-0 6–Drive P/N 501357-01-1 Tools Required: • Flat-blade Screwdriver • Number 2 Phillips Screwdriver • 1/4-inch Hex Nutdriver 7.15.1 Drive Bay PCBA Removal Turn off the TLS power and remove the power cord. Remove the Top Panel (Section 7.4.1).
  • Page 136 PWRDST Rear View of TLS PCBA Mounting Screws (3) D1PWR D1CNTL D2PWR D2CNTL POWER YCLEAR Figure 7-34 Drive Bay PCBA (42xx model shown) NOTE In the next step, the nuts on the back of the PCBA mounting screws come loose when the screws are removed.

  • Page 137: Carousel Pcba

    PCB/500617-01-4 and PCB/500617-02-2. The -01 version uses a 20-pin, verti- cal CAROSL (Carousel) connector, while the -02 version uses a 20-pin, right- angle CAROSL connector. The TLS-4000 models require the -01 version with the vertical CAROSL connector. Field–Replaceable Units (FRUs) 7-55 501380 Rev.
  • Page 138 7.16.1 Carousel PCBA Removal Carousel Motor Power Cable Connector Carousel Gear Guard CAROSL Cable Connector Carousel PCBA Carousel Position Sensor (Optical Switch Pair) PCBA Mounting Screws (3) PCBA Alignment Pin PCBA Spacer (3) Figure 7-35 The Carousel PCBA (3 Views) Turn off the TLS power and remove the power cord.

  • Page 139: Carousel Motor

    cabinet. When the Carousel Position Sensor is in front of the Carousel Gear Guard, slide the Carousel PCBA towards the cabinet door to remove it (Figure 7-35). 7.16.2 Carousel PCBA Replacement CAUTION In the next steps, be careful not to damage the Carousel Position Sensor on the Carousel Gear Guard (Figure 7-35), as you install the Carousel PCBA.
  • Page 140 Remove the right Side Panel (Section 7.4.3). Open the cabinet door. For TLS models 4440 and 4480 only, follow the procedure in Section 7.9 to re- move the I/O port assembly. Use a number 2 Phillips screwdriver to remove all three mounting screws from the Upper Carousel Pivot Support (Figure 7-36), then lift the Upper Carousel Pivot Support up out of the TLS (Figure 7-37).
  • Page 141 Upper Carousel Pivot Support Upper Carousel Bearing Upper Carousel Bearing Upper Carousel Pivot FRONT Carousel Gear Guard Carousel Gear Lower Carousel Bearing Mounting Screws (4) TLS Midplate Motor Cable Carousel Motor Shaft Gear Figure 7-37 A Carousel Assembly Disconnect the Carousel Motor cable from the Carousel PCBA (Figure 7-35). For TLS models 4660 and 46120, remove any nylon cable ties that are attached to the motor cable (Figure 7-38).
  • Page 142 Use a 3/32-inch Allen wrench to remove all four Carousel Motor mounting screws (Figure 7-37). Remove the Carousel Motor from the cabinet. 7.17.2 Carousel Motor Replacement Align the mounting holes in the Carousel Motor with the corresponding mount- ing holes in the TLS’ Midplate, so that the motor’s cable faces the rear of the TLS (Figure 7-37).

  • Page 143: Scsi High Voltage Differential Adapter Pcba

    7.18 SCSI High Voltage Differential Adapter PCBA P/N 501407-01-1 Tools Required: • Number 2 Phillips Screwdriver Mounting Screws Rear Service Panel Figure 7-39 TLS Rear View 7.18.1 SCSI High Voltage Differential Adapter PCBA Removal Turn off the TLS power and remove the power cord. Use a number 2 Phillips screwdriver to remove all six Rear Service Panel mount- ing screws (Figure 7-39), then remove the panel.
  • Page 144 Executive PCBA PCBA Spacers (3) SCSIID Male WADAPT on HVD Adapter Female WADAPT on Executive SE/LVD or LVD/SE Figure 7-40 HVD Adapter PCBA 7.18.2 SCSI High Voltage Differential Adapter PCBA Replacement This procedure assumes that the PCBA was removed in Section 7.18.1. Insert all three PCBA spacers on the HVD Adapter PCBA into the mounting holes in the Executive PCBA making sure that the female WADAPT connector is aligned with the male ADAPT connector on the Executive PCBA.

  • Page 145: Q-Link

    7.19 Q-Link P/N 501657-01-9 Tools Required: • Number 2 Phillips Screwdriver Mounting Screws Q-Link Figure 7-41 Q-Link on Rear of TLS 7.19.1 Q-Link Removal Turn off the TLS power and remove the power cord. Use a number 2 Phillips screwdriver to remove all six Q-Link panels mounting screws (Figure 7-41), then move the panel backwards to access the cables.
  • Page 146 Executive PCBA SERIAL Connector SERIAL Ribbon Cable AUXPWR Connector (behind ribbon cable) AUXPWR Cable Q-Link PCBA SERIAL Connector POWER Connector Figure 7-42 Detail of AUXPWR and SERIAL Cable Connections on Q-Link PCBA 7.19.2 Q-Link Replacement This procedure assumes that the PCBA was removed in Section 7.19.1. Connect the AUPWR cable to the POWER connector on the Q-Link PCBA as shown in Figure 7-42.

  • Page 147: After-Maintenance Test Procedures

    7.20 After-maintenance Test Procedures The maintenance procedures listed below do affect the TLS’ calibration. After any of these procedures are completed, follow the instructions in Section 5.3.2 to recalibrate the TLS. • Remove and replace the Carriage Assembly. • Remove and replace the Carriage Assembly PCBA. •...

  • Page 148: Firmware Updating

    Q-Link Web Interface. The Q-Link Web Interface firmware can only be uploaded through its LAN or Internet connection. NOTE Firmware should only be updated after consulting with Qualstar’s Technical Support Department. They can be reached at (805) 583-7744 or E-mail them at support@qualstar.com Board Name...
  • Page 149 Remove the six Phillips screws securing the service panel on the rear of the li- brary. Refer to Figure 8-1. Care must be taken to not remove the four screws se- curing the heatsink panels. Phillips Screws (6) Location of Part Number on Executive PCBA Do not remove these screws...

  • Page 150: Firmware Update Via The Scsi Of Fibre Channel Interface

    Table 8-3 Steps to View the Display Revision Status Screen In all TLS-4000 models with Executive III or IV boards a Drive Bay board is util- ized to interface the tape drives to the Executive board. There are three sizes of Drive Bay boards (2-drive, 4-drive and 6-drive) and each contains a programmed micro-controller I.C.
  • Page 151 2255 In this example, the SCSI bus scan found three devices. The first device is a Qualstar TLS-4660, followed by two Quantum Tape Drives. NOTE Upload.exe will not work if the Id is greater than 15, or the Lun is greater than 7 when updating the firmware in a fibre channel environment.

  • Page 152: Firmware Update Via Q-Link

    Do not turn off TLS power while the update is in progress. The last packet is number 512. The TLS will begin the firmware update process. Wait for the following message to appear on the library’s display: FIRMWARE UPGRADE System Firmware is being changed;...
  • Page 153 Figure 8-2 Sample of the Library Firmware Upload Screen Access the firmware file by either clicking on the Browse button or typing the file path to the firmware file. Press the enter key or click on the Upload Firmware button to begin the upload- ing process.
  • Page 154 Figure 8-4 Sample of the Library Firmware Upload Progress Screen Figure 8-5 Sample of the Library Firmware Reprogramming Progress Screen Firmware Updating 501380 Rev. B...

  • Page 155: Firmware Update Via Q-Conn

    This cable must have female DB-9 connectors at each end and wiring such that pins 2 and 3 are crossed over and pins 5 are connected to each other at both ends. See Table 8-4. User’s Qualstar Host Computer Library...
  • Page 156 Figure 8-7 TLS Remote Front Panel Program Displayed in HyperTerminal Select the Configure button to set the communications parameters for a baud-rate of 9600, with 8 data bits, no parity, one stop bit and no flow control. See Figure 8-9. Figure 8-8 Properties Screen Firmware Updating 501380 Rev.

  • Page 157: Vt100 Terminal Emulation

    Figure 8-9 Configure Screen Under the Properties Menu 8.4.4 VT100 Terminal Emulation Use the Settings dialog tab to configure the application for File\Properties VT100 terminal emulation. You may also consider parameters to sat- ASCII Setup isfy your display requirements. 8-10 Firmware Updating 501380 Rev.
  • Page 158 Figure 8-10 Settings Screen Under the Properties Menu Figure 8-11 ASCII Setup Screen under Settings Screen Firmware Updating 8-11 501380 Rev. B...

  • Page 159: Remote Library Command Mode

    Do not turn off TLS power while the update is in progress. If the entire firmware object file is successfully downloaded, the TLS will reprogram itself and then restart automatically. Once the library restarts, the user will see the Qualstar Remote Library Control Panel. 8.4.6.1 Example of a download session Enter the command “...
  • Page 160 Figure 8-13 Example of Xmodem Firmware Download Use the HyperTerminal menu function , to download the Transfer->Send File TLS firmware file to the library. TLS firmware object files are typically named 700105.211 where 700105 represents the code-set name and 211 is the Version (Ver- sion 2.11 in this example).

  • Page 161: Procedure For Replacing The Flash Memory I. C. On Executive I Boards

    This procedure will lead you through the process of changing the TLS operating firm- ware on an Executive I board. It involves removing the rear service panel and replac- ing a 32-pin, DIP Flash-EPROM memory integrated circuit (IC). Contact Qualstar Technical Support to obtain the necessary integrated circuit (the Part Number is 700099).
  • Page 162 700099 Pin 1 Figure 8-16 500657-01-0 Executive I PCBA Install the new 700099 Flash-Memory IC at U10. Note the orientation of pin 1. Make certain that all pins are fully inserted into the socket. Replace the access panel and secure it with the six Phillips screws. Connect the power cord and switch the power on.

  • Page 163: Procedure For Replacing The Flash Memory I.c. On Executive Iii Or

    8.4.8 Procedure for Replacing the Flash Memory I.C. on Executive III or IV Boards This procedure will lead you through the process of changing the TLS operating firm- ware on an Executive III or IV board. It involves removing the rear service panel and replacing a 32-pin, DIP Flash-EPROM memory integrated circuit (IC).

  • Page 164: Procedure For Replacing The Flash Memory I.c. On Drive Bay Boards

    This procedure will lead you through the process of changing the operating firmware on a TLS-4000 Drive Bay Board. It involves opening a drive access hatch or removing a drive access panel and replacing a 28 pin DIP Micro-controller integrated circuit (IC) on the Drive Bay board.
  • Page 165 Drive Access Panels 1/4-turn 1/4-turn Fasteners (4) Fasteners (3) 44xx Series 46xx Series Figure 8-19 Rear View (44xx and 46xx shown) Locate the Drive Bay PCBA (Figure 8-20). Remove the Flash-Memory IC from the Drive Bay board (see Figure 8-21) using a flat blade screwdriver or equiva- lent tool.
  • Page 166 Located at U2 Located at U3 700108 700108 Pin 1 Pin 1 Located at U3 700111 Pin 1 46xx Series 44xx Series 42xx Series Figure 8-21 Drive Bay Boards: 6X, 4X and 2X Install the new Flash-Memory IC on the Drive Bay PCBA. Note the orientation of pin 1.
  • Page 167 After replacing the Flash-Memory IC on a 42xx series library, close the Drive Access Hatch, then fasten it by turning the two 1/4-turn fasteners clockwise. On 44xx and 46xx series libraries align the Drive Access Panels three or four (model dependent) 1/4-turn fasteners with the corresponding receptacles on the rear panel, then fasten it by turning the 1/4-turn fasteners clockwise.

  • Page 168: Tls Expansions

    This chapter contains installation instructions for each TLS expansion kit. To replace an existing FRU (Field-Replaceable Unit), follow the instructions in Chapter 7. A number of expansion kits are available from Qualstar. Some expansion kits are used to increase the cartridge capacity of some TLS models, while other expansion kits are used to add a Barcode Reader (Section 9.3) to any TLS model.

  • Page 169: Model Expansions

    9.2.1 Installing a Model Expansion Kit This procedure requires one expansion kit (described in Figure 9-1), plus a number 2 Phillips screwdriver to install the hardware. Locking Tabs Magazine Locking Tabs Mechanism Qualstar P/N 501110-02-1 Figure 9-2 8mm Magazine Mechanism TLS Expansions 501380 Rev. B...
  • Page 170 9.2.1.1 Model 4212 to Model 4222 Expansion This procedure replaces the Midplate, and adds a Carousel and two Receivers. Receiver Assembly Mounting Plate Screws (5) Midplate Top View Receiver Assembly Mounting Plate Screws (5) Midplate Mounting Screws (2) Receiver Assembly Mounting Plate Receiver Assembly Mounting Plate...
  • Page 171 Midplate mounting screws (4) Left Side of TLS Right Side of TLS Figure 9-4 Midplate mounting screws From the left and right side of the TLS remove the four Midplate mounting screws (Figure 9-4). From the inside of the TLS the remove two Midplate mounting screws (Figure 9-3), then remove the Midplate from the TLS.
  • Page 172 9.2.1.1.2 Adding the Carousel Midplate Rear of TLS Carousel PCBA Carousel Motor Cable Carousel Motor Power Cable Connector Midplate Screw Holes (6) Top View of Carousel Midplate Front of TLS Carousel Motor Carousel Midplate Power Cable Connector Carousel Motor REAR VIEW Figure 9-5 The Carousel Midplate with Motor and PCBA Place the Carousel Midplate in the TLS and align it with the six mounting holes in the top of the drive bay sides.
  • Page 173 CAROSL Cable Executive PCBA Frame of TLS Upper Opening Tie Wrap Holes (6) Nylon Cable Tie Pair (3) Lower Opening Figure 9-6 CAROSL Ribbon Cable Attached to TLS Frame NOTE Six Nylon Cable Ties will be needed to secure the CAROSL ribbon cable to the TLS frame. Thread the CAROSL cable through the upper opening in the TLS frame as shown in Figure 9-6.
  • Page 174 Thread the CAROSL cable through the lower opening in the TLS frame as shown in Figure 9-6. Thread the CAROSL ribbon cable under the Midplate and attach it to the CAROSL connector on the Carousel PCBA. See Figure 9-7. CAROSL Cable Connector Carousel Motor Power Cable Connector...
  • Page 175 CAUTION Be careful not to damage the Carousel Position Sensor with the Carousel Gear Guard when you install the Carousel (Figure 9-7 and Figure 9-8). Insert the Carousel through the open cabinet door. Align the lower Carousel Bearing with the TLS Frame, then lower the Carousel down into place (Figure 9-8).
  • Page 176 Use four 6-32 x 3/8-inch screws to install a new Receiver Assembly onto the up- per half of the empty Carousel face. Use two 6-32 x 5/8-inch screws to install a new Receptacle Assembly above the new top Receiver. Use the uppermost set of holes. Rotate the Carousel by hand 180 to access the other empty Carousel face.

  • Page 177: Entering The Update Password

    Receiver Carousel Face Mounting Holes Mounting Holes Receiver Carousel Face Mounting Holes Mounting Holes Locking Tabs Carousel Face Receiver Figure 9-11 Hole patterns for mounting receivers on carousels 9.2.1.3 Model 4660 to 46120 Expansion Refer to Figure 9-10. Follow the procedure in Section 9.2.1.2 to install the new hardware for the model 4660 –...

  • Page 178: Reconfiguring The Model Number

    LCD pointing to Configuration Press the ENTER key to enter the menu. Configuration NOTE See the TLS-4000 Installation and Operation Manual (Qualstar document number 501370) for complete details about the Configuration menu. Press the ENTER key to enter the menu.

  • Page 179: Recalibrating The Unit

    9/64-inch Allen Wrench • Number 2 Phillips Screwdriver • A TLS-4000 Installation and Operation Manual (Qualstar document num- ber 501370) NOTE A barcode reader expansion kit contains a Barcode Reader, with attached bracket and cable, and two 6-32 x 1/4-inch flat-head screws.

  • Page 180: Barcode Reader Installation

    Access Hole in rear of Barcode Reader Cable Mounting Screws Insertion Axis Motor Figure 9-12 The TLS-4000 Carriage Assembly – Top View 9.3.2.1 Installing the Barcode Reader Hardware Refer to Figure 9-12. Turn off the TLS power and remove the power cord.
  • Page 181 Gently turn the Allen wrench counter–clockwise to move the Gripper forward, until both Barcode Reader mounting screw holes are accessible, then remove the wrench. Position the Barcode Reader under the Carriage Assembly, with the mounting holes in the bracket facing up, and the Barcode Reader’s cable jack facing the cabinet door.
  • Page 182 ) and prevent unauthorized access CESS Update to the Private menu. 9.3.2.6 Barcode Label Check Characters Follow the instructions in the TLS-4000 Installation and Operation manual (501370) to properly configure the value. LabelCheckChar 9.3.2.7 Testing the Barcode Reader Turn the TLS power off, then open the cabinet door.

  • Page 183: I/O Port

    Qualstar P/N 500750-02-1 for TLS-4212 Models • Number 2 Phillips Screwdriver • A TLS-4000 Installation and Operation Manual (Qualstar document number 501370) NOTE An I/O port kit contains an I/O port with attached circuit board and five mounting screws. Kit P/N 500750-02-1 will also contain two single slot receptacles.
  • Page 184 CAUTION The unit must be recalibrated after the I/O port assembly is installed in the TLS. NOTE If desired, remove a Side Panel (Section 7.4.3), to gain easy access to the I/O port assembly ca- ble assembly’s plug through the holes in the side of the TLS’ frame. Front Rear I/O Port...
  • Page 185 9.4.2.2 Removing or Replacing Receptacles Continue to Section 9.4.2.3 if the I/O port is being installed in a TLS-4210 library. TLS-4212 models must have the dual slot receptacles replaced with single slots and the TLS-4222s must have the receptacles removed before installing the I/O port. For TLS-4212 models only, use a number 2 Phillips screwdriver to remove the two screws securing a dual slot receptacles bracket to the carousel and remove the receptacles.
  • Page 186 Support the I/O port assembly with one hand and install all five mounting screws (Figure 9-13). Plug the I/O port ribbon cable into the IOPORT connector on the PCBA (Figure 2-8). Gently press the Call switch button back onto the Call switch. If you removed a Side Panel, reinstall it (Section 7.4.4), then reinstall the top Panel (Section 7.4.2).
  • Page 187 9.4.2.7 Clearing the Password Follow the instructions in Section 5.3.3 to execute the Private menu's CLEAR AC- command, to remove the password ( ) and prevent unauthorized access CESS Update to the Private menu. 9.4.2.8 Recalibration Recalibrate the TLS. (See Section 5.3.2 for details.) 9-20 TLS Expansions 501380 Rev.

  • Page 188: System Interconnect Diagram

    System Interconnect Diagram System Interconnect Diagram 10-1 501380 Rev. B...

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