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

FIN #: I0832-1

Create Date: Jun/06/02

Keywords: 

CPU shroud inserts were installed incorrectly in Sun Blade 1000, Sun Blade 2000, Netra 20 and Sun Fire 280R systems, causing increased resistance during insertion/removal of CPU modules

SunAlert: No

Top FIN/FCO Report: No

Products Reference: CPU shroud

Product Category: Server / Service

Product Affected: 

Systems Affected:
-----------------
Mkt_ID   Platform   Model   Description           Serial Number
------   --------   -----   -----------           -------------
  -        A29       ALL    Sun Blade 2000              -
  -        A28       ALL    Sun Blade 1000              -
  -        N28       ALL    Netra 20                    - 
  -        A35       ALL    Sun Fire 280R               -


X-Options Affected:
-------------------
Mkt_ID   Platform   Model   Description   Serial Number
------   --------   -----   -----------   -------------
  -         -         -          -              -

Parts Affected: 

Part Number        Description                   Model
-----------        -----------                   -----
F540-4136-06       ASSY Shroud Excalibur           -

References: 

N/A

Issue Description: 

CPU shroud inserts for Sun Blade 1000, Sun Blade 2000, Netra 20 (T4) or
Sun Fire 280R systems may have been improperly installed during
manufacture.  The four CPU shroud inserts (to which the CPU module
captive screws attach) may exhibit angles greater than the specified .5
degree from vertical, thus causing increased resistance during
insertion/removal of the CPUs.  

In some cases, it may be impossible to install or remove a CPU module
without damaging the hardware.  If higher than average resistance is
felt during the CPU installation/removal process and the user does not
adhere to the recommended techniques, there is a likelihood that the
Mictor connectors on the motherboard can be damaged or the CPU captive
screw hardware may break.

This misalignment/angularity of the CPU shroud insert is difficult to
detect in most cases, although extremely out-of-tolerance inserts are
most likely to appear on the unpopulated locations for single-CPU
units.  Gross misalignment/angularity on populated CPU locations is not
as likely since this would have been caught in the manufacturing
process due to the difficulty of insertion.

The most common symptom of this defect is exhibited as an increased 
CPU insertion/removal force, stripped screws/inserts, e-clips falling
off the screw and, less likely, damage to the Mictor connectors on 
the motherboard.

Inserts in the CPU mounting shroud were improperly installed at angles
greater than the .5 degrees shown in the product specification.
Screened shrouds have shown a variation between 0.35 degrees and 4.0
degrees from vertical.  From available data (i.e. first article data
and measurements of current shrouds), this out-of-tolerance condition
has been in existence since the first release of these platforms.

Symptoms attributed to this condition (i.e. difficulty in
insertion/removal of CPUs) is further magnified when the correct
installation/removal process is not followed. 

The problem was root caused to the ultrasonic welding tool used to
install the inserts into the plastic shroud, as well as, the fixturing
used to secure the part during this process.  Wear on the tooling and
variations in the swivel fixture used to hold the part resulted in
deviations in the insertion angles.  Further investigation found that
the angularity of the inserts was never initially specified to be a
critical-to-function dimension and so no checks for this value were
ever performed.  
 
The existing tooling has been reworked at the supplier to ensure less
angularity (i.e. the tool surface has been leveled so that the tool
comes down flush to the surface of the plastic part) and the tooling
surface is checked twice per shift to ensure surface integrity.  The
supplier is also currently sampling 1 shroud per shift and inspecting
them for a maximum of .72 degrees angularity.  A complete audit of the
supplier by Celestica confirmed the corrective actions and yielded no
major non-conformances.  

Despite the fact that this out-of-spec condition has been in existence
for quite some time, catastrophic failure should only occur when the
inserts are aligned at greater than a 3 degree angle.  Smaller
misalignments/angularity should only cause greater resistance in
insertion/removal force so long as the proper technique (described
below) is used.

Implementation: 

---
        |   |   MANDATORY (Fully Proactive)
         ---    
         
  
         ---
        |   |   CONTROLLED PROACTIVE (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. 

Because it is difficult to visually confirm whether the CPU shroud
insert is misaligned, Field personnel should adhere to the CPU
removal/insertion method described below for all cases:
     
To INSERT CPU Modules
---------------------

  1. Turn thumbscrews by hand to locate screws in thread.

  2. Turn one screw a quarter turn clockwise and then turn opposite
     screw a quarter turn clockwise using the provided torque tool in 
     the unit.

  3. Repeat above step until both screws lock and the CPU module is 
     securely in place.

  4. Repeat steps 1-3 for other CPU module (if present).

  The above steps are instructions given to Manufacturing and have
  proven to be effective in preventing damage to the Mictor connectors
  on the motherboard and the CPU screws.

  NOTE: If the above method is ineffective in inserting the CPU
	modules, there may be a gross misalignment in the shroud
	inserts.  Replacement of the entire CPU shroud (540-4696-02)
	may be necessary.
     
To REMOVE CPU Modules
---------------------
     
  1. Turn one screw a quarter turn counter-clockwise and
     then turn opposite screw a quarter turn counter-clockwise using
     the provided torque tool in the unit.

  2. Repeat above step until both screws are completely
     backed out and the CPU module can be removed from the shroud.

  3. Repeat steps 1-2 for other CPU module (if present)

  NOTE: Connectors are extremely sensitive - please handle modules
        by thumbscrews only.

Comments: 

None

============================================================================

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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