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- Sun Proprietary/Confidential: Internal Use Only -
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                            FIELD INFORMATION NOTICE
                  (For Authorized Distribution by SunService)

FIN #: I0675-1

Create Date: Jul/26/01

Keywords: 

The current E10000 System Board insertion technique places improper loads on the System Board/Centerplane mating connector and may damage the connector.

SunAlert: No

Top FIN/FCO Report: No

Products Reference: E10K System Board insertion technique

Product Category: Server / Service

Product Affected: 

Mkt_ID   Platform   Model   Description              Serial Number
------   --------   -----   -----------              -------------
Systems Affected
----------------
  - 	  E10000     ALL    Ultra Enterprise 10000         -

X-Options Affected
------------------
  -          -        -           -                         -

Parts Affected: 

Part Number   Description                           Model
-----------   -----------                           -----
240-4111-01   Guide PIN HDM CPLANE ROUND-TIP          -
565-1695-01   KIT PWR MDL REPLACEMENT                 -

References: 

BugId:  4247006

ECO:    WO_18750
        WO_21132

URL:    http://sdpsweb.ebay/FIN_FCO/FIN/FINI0675-1_dir/SystemBoardInstall.html

Issue Description: 

The current E10000 System Board insertion technique puts the System
Board and Centerplane mating connectors (the Power Modules, in
particular) at risk of severe damage.  The risk increases each time a
System Board is ejected or inserted.  Once damage occurs, the only method
of repair is System Board or Centerplane replacement.

The problem is a design flaw in the connector system used on the E10000
System Board and the Centerplane.  The design forces the Power Module
portion of the connector to support the entire weight of the rear of
the System Board during both insertion and ejection, rather than the
guide pins.  As the Power Modules are not designed to provide such
loading, the stress loosens and misaligns the modules on the
Centerplane.  Subsequent insertions/ejections further loosen and
misalign the power modules until they come off completely, or are
severely out of alignment.  Any further system board insertions results in
irreverseable connector damage to either the System Board, the
Centerplane, or both.  Damage of this type can only be repaired at the
factory, thus requiring replacement of the damaged assembly.

The guidance mechanism of the System Board, Card Cage, and Centerplane
are designed such that the connnector/guide pin "lift" the rear of the
System Board into proper alignment during insertion.  The intent is that
the Centerplane guide pins provide the "lifting" force via its tapered
point.  Analysis has revealed that the power module shroud is too long,
and makes contact with its mating connector before the guide pins
engage and safely "lift" the System Board into proper alignment (the
centerplane guide pins are already as long as they can be).  Thus,
during the insertion process, the weight of the rear of the System
Board is lifted by the Power Module portion of the connector.
The power modules are not designed to provide and such "lifting" force,
and thus easily become loose and misaligned.  Once misaligned, the very
high insertion forces generated by the System Board insert/eject
handles crush the connectors on the System Board and Centerplane,
requiring total assembly replacement.

It has been demonstrated that a revised System Board insertion technique
that "unweights" the rear of the System Board will greatly reduce the
occurrence of such damage.  The technique is detailed in the document
located at:

   http://sdpsweb.ebay/FIN_FCO/FIN/FINI0675-1_dir/SystemBoardInstall.html      

In addition, a new guide pin with a revised tip profile (p/n:
240-4111-01) has been designed and qualified by Sun, and will be
configured at the factory into all new production and reworked
Centerplanes as ECO 21132 is released on 6/30/01.  There is currently
no qualified field Guide Pin replacement kit/field upgrade procedure
available at this time.

Also, a Centerplane power module repair kit/procedure (p/n:
565-1695-01) is being developed that will allow loose power modules to
be replaced in the field without the need for Centerplane replacement.

   NOTE: The kit will only be used to remedy "loose" power modules
         that are undamaged; Centerplanes with "damaged" power modules 
         can only be repaired at the factory - thus requiring Centerplane
         replacement).

Finally, it has been noted that the Power Module of the System Board
can easily become damaged/misaligned through handling.  This
damage/misalignment, if unnoticed, can induce damage to the mating
Centerplane power module.  In response to this, a new protective flange
has been added to all new and factory reworked System Boards since
5/01/01 per ECO 18750.

Implementation: 

---
        |   |   MANDATORY (Fully Pro-Active)
         ---    
         
  
         ---
        |   |   CONTROLLED PRO-ACTIVE (per Sun Geo Plan) 
         --- 
         
                                
         ---
        | X |   REACTIVE (As Required)
         ---

Corrective Action: 

The following recommendation is provided as a guideline for authorized
Enterprise Services Field Representatives who may encounter the above 
mentioned problem:

When replacing a system board in an E10000 system, follow the board
insertion techniques described in the document located on the 
following URL.

   http://sdpsweb.ebay/FIN_FCO/FIN/FINI0675-1_dir/SystemBoardInstall.html

Comments: 

NOTE: The power module replacement kit (565-1695-01) is NOT available
      until it becomes GA status on 11/1/01. 

Of all the changes in process to remedy the problem of System
Bd/Centerplane connector damage, training and practicing the new
"unweighting" technique is by far the single most effective benefit to
E10000s already deployed around the world.

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Implementation Footnote: 

i)   In case of MANDATORY FINs, Enterprise Services will attempt to    
     contact all affected customers to recommend implementation of 
     the FIN. 
   
ii)  For CONTROLLED PROACTIVE FINs, Enterprise Services mission critical    
     support teams will recommend implementation of the FIN  (to their  
     respective accounts), at the convenience of the customer. 

iii) For REACTIVE FINs, Enterprise Services will implement the FIN as the   
     need arises.
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