Document Audience:INTERNAL
Document ID:A0182-2
Title:Systems with 18.2GB and 36GB IBM disk drives may experience higher than expected failure rate.
Copyright Notice:Copyright © 2007 Sun Microsystems, Inc. All Rights Reserved
Update Date:Mon Feb 07 00:00:00 MST 2005

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                       FIELD CHANGE ORDER
        (For Authorized Distribution by Sun Services)

 

FCO #: A0182-2
Status: inactive
Synopsis: Systems with 18.2GB and 36GB IBM disk drives may experience higher than expected failure rate.
Date: Feb/07/2005
Top FIN/FCO Report: No

PRODUCT REFERENCE: 18.2GB / 36GB IBM disk drives
Product Category: Storage / Disk
Product Affected: 
Systems Affected:
------- --------
Mkt_ID    Platform      Model   Description               Serial Number
------    --------      -----   -----------               -------------
  -	  Anysys	  -	System Platform Independent	-

X-Options Affected
--------- -------
Mkt_ID     Platform      Model    Description        Serial Number
------     --------      -----    -----------        -------------
  -          -             -          -                   -
Parts Affected: 
Part Number     Description
-----------	-----------
540-4520-01	DRV ASSY 36GB 1 SCSI SPUD&PLAT	- 	- 	-
540-4178-01	DRV ASSY 18GB 10K 1 SCSI W/SPU	- 	- 	-
540-4177-01	DRV ASSY 18GB 10K 1 SCSI W/SPU

(SCSI Devices)
Type    Vendor    Model     SerialNumber(Min)    SerialNumber(Max)    Firmware
----    ------    -------   ------------------   ------------------   --------
Disk	IBM	  DDYST36950         -                   -               -
Disk	IBM	  DDYST18350         -                   -               -
References: 
BugID: 4490041
  SunAlert: 40130
  WWStopShip: P200-20006
  DPCO:	278.A
  FIN: I0724-2
  ESC: 541752	ics/ p/ 2hr/ 2 failed A3500 18GB hdds
Issue Description: 
IBM Discovery model disk drives installed in Sun systems may experience
higher than expected failure rate under certain circumstances, due to Head
Disk Interference (HDI).  This reliability issue can negatively impact
customer operations.

This issue only affects IBM Discovery 18GB and 36GB drives with the
following part numbers:

         ---------------------------------
        | Sun P/N   | Vendor Model Number |
        |===========+=====================|
        | 540-4520  | IBM DDYST36950      |
        | 540-4177  | IBM DDYST18350      |
        | 540-4178  | IBM DDYST18350      |
         ---------------------------------

When this isue occurs, the following error code indicates that a drive
has failed due to an HDI occurrence:  "Sense Code 02x04".

Sample error messages:

      /sbus@7,0/QLGC,isp@0,10000/sd@1,0 (sd46):
      Error for Command: write                   Error Level: Fatal
      Sense Key: Hardware Error
      ASC: 0x2 (no seek complete), ASCQ: 0x0, FRU: 0x0

     10098107  c1t8d0   540-4178-01  DDYS-T18350  01061XE682


      /sbus@7,0/QLGC,isp@0,10000/sd@1,0 (sd46):
      Error for Command: read                    Error Level: Fatal
      Sense Key: Vendor Unique
      ASC: 0x80 (), ASCQ: 0x0, FRU: 0xa

     10102117  c2t10d0  540-4178-01  DDYS-T18350  01061XE522  108305

      /sbus@7,0/QLGC,isp@0,10000/sd@a,0 (sd54):
      Error for Command: read                    Error Level: Fatal
      Sense Key: Media Error
      ASC: 0x11 (unrecovered read error), ASCQ: 0x0, FRU: 0x0

     10102117  c1t5d0   540-4178-01  DDYS-T18350  01061XE630  108305

      /sbus@3,0/QLGC,isp@0,10000/sd@0,0 (sd15):
      Error for Command: write                   Error Level: Fatal
      Sense Key: Media Error
      ASC: 0x3 (peripheral device write fault), ASCQ: 0x0, FRU: 0x0

     10088635  c2t13d0  540-4178-01  DDYS-T18350  01061XE750

      /sbus@6,0/QLGC,isp@1,10000/sd@d,0 (sd42):
      Error for Command: load/start/stop         Error Level: Retryable
      Sense Key: Not Ready
      ASC: 0x4 (LUN not ready), ASCQ: 0x0, FRU: 0x0

     10096449  c2t9d0   540-4178-01 DDYS-T18350  01061XE634


ROOT CAUSE ANALYSIS:

When the drives are subjected to excessive idle time (several hours),
the Head Air Bearing Surface (ABS) may pick up excessive disk
lubricant in the cavity of the ABS.  This buildup of excessive
lubricant results in unstable flying characteristics with the ultimate
outcome of Head Disk Interference (HDI) and subsequent drive failures.
The fix is to use non-IBM drives for the affected part numbers listed
in this FCO.

Corrective action was implemented in Manufacturing by purging all suspect
IBM Drives via Worldwide Purge P200-20006 issued on August 25, 2001.
Corrective Action was put in place in Enterprise Services via DPCO# 278
on Janurary 24, 2002.
Implementation: 
---
|   |   MANDATORY (Fully Pro-Active)
 ---

 ---
|   |   CONTROLLED PRO-ACTIVE (per Sun Geo Plan)
 ---

 ---
| X |   UPON FAILURE
 ---
Replacement Time Estimate: 
0.5 hours
Special Considerations: 
This FCO will have a time zone phased relaease based on material
readiness as follows:

		Readiness Date
		--------------
  US/Canada	Feb/07/2005
  Ltn America	Dec/23/2004
  EMEA		Feb/07/2005
  APac		Nov/30/2004
  Japan		Nov/30/2004

The above dates represent when each time zone has determined that
it will be materially ready to support this FCO.
Corrective Action: 
Upon failure per above described failure mode, replace as follows;

  replace 540-4177-01 (IBM Only) with 540-4177-01 (Non IBM)

  replace 540-4178-01 (IBM Only) with 540-4178-01 (Non IBM)

  replace 540-4520-01 (IBM Only) with 540-4520-01 (Non IBM)

IDENTIFICATION OF AFFECTED PARTS (how to):

 For all systems, to determine if a system has one of these affected IBM
 Discovery drives, do one of the following:

    . If the system is down, run the "probe-scsi" command from the "ok"
      prompt.

    . If the system is up, run the "format" command.

    . If Explorer has run, check the file /opt/SUNWexplorer/bin/diskinfo.

 For A1000/A3x00 Arrays attached to a host, an alternative would be to
 run one of the two following commands:

    A. run #/usr/lib/osa/bin/drivutil -i

          Ex: #/usr/lib/osa/bin/drivutil -i c1t0d0

    B. From RM6 GUI,

          RM6 GUI -> Configuration -> Module -> Profile -> drives
Comments: 
None

________________________________________________________________________

NOTE: FCO Tracking Instructions for Radiance/SPWeb:
--------------------------------------------------

If a Radiance case involves the application of an FCO to solve a customer
issue, please complete the following steps in Radiance/SPWeb prior to
closing the case:
 
    o Select "Field Change Order" in the REFERENCE TYPE field.

    o Enter FCO ID number in the REFERENCE ID field.
      For example; A0222-1.

If possible, include additional details in the REFERENCE SUMMARY field
(ie. Upgrade complete, customer declined, etc.)
________________________________________________________________________

Implementation Notes
--------------------

In case of "Mandatory" FCOs, Sun Services will attempt to contact
all known customers to recommend proactive implementation.

For "Controlled Proactive" FCOs, Sun Services mission critical
support teams will initiate proactive implementation efforts for
their respective accounts, as required.

For "Upon Failure" FCOs, Sun Services and partners will implement
the necessary corrective actions as the need arises.

The CIC process must be used for proactive hardware replacement
requests when an FCO is classified as "Upon Failure".


Billing Information
-------------------

Warranty: Sun will provide parts at no charge under Warranty
          Service.  On-Site Labor Rates are based on specified
          Warranty deliverables for the affected product.

Contract: Sun will provide parts at no charge.  On-Site Labor Rates
          are based on the type of service contract.

Non Contract: Sun will provide parts at no charge.  Installation by
              Sun is available based on the On-Site Labor Rates
              defined in the Price List.

________________________________________________________________________

All FCO documents are accessible via Internal SunSolve.  Type "sunsolve"
in a browser and follow the prompts to Search Collections.

For questions on this document, please email:

    [email protected]

The FIN and FCO homepage is available at:

    http://sdpsweb.central/FIN_FCO/index.html

For more information on how to submit an FCO, go to:

    http://sunwebcollab.central.sun.com:80/gm/folder-1.11.699489

To access the Service Partner Exchange, use:

    https://spe.sun.com

________________________________________________________________________
Statusinactive