3.6 Replacing Components

This section provides procedures replacing enclosure components. All of the components described here are customer-replaceable units (CRUs).

This section describes the following replacement tasks:

To Replace a Fan Module
To Replace the Front Indicator Board
To Replace a Hard Disk Drive
To Replace the Power Distribution Board
To Replace a Power Supply
To Replace the System Controller Module

To Replace the Array Chassis

Caution - Before handling components, attach an ESD wrist strap to a grounding location on the chassis (see Sun Storage J4500 Array Internal Components). The enclosure's printed circuit boards and hard disk drives contain components that are extremely sensitive to static electricity.

To Replace a Fan Module

Each fan module (also known as a fan tray) has two fans. The array enclosure has five fan modules (for a total of 10 fans in the enclosure). This component is customer replaceable.

Note - Enclosure cooling might be affected by dust and contaminant build-up. It is recommended that the enclosure be opened and checked approximately every six months or more often in dirty operating environments. Check component heatsinks, fans, and air openings. If necessary, clean the enclosure by brushing or blowing contaminants or carefully vacuuming contaminants from the enclosure.

Caution - The fans are hot-swappable and can be removed and replaced while the array is running. Do not keep the fan tray access cover open for more than 60 seconds at a time to avoid overheating the array enclosure. Remove and replace only one fan module at a time.

Fans are labeled FT0 (fan tray 0) to FT4 (fan tray 4). See 3.5 Internal Component Locations.

If the array enclosure is in a rack, slide it far enough out of the rack so that you can access the fan modules.
From the front of the enclosure, open the fan tray access cover.
Using a No. 2 Phillips screwdriver, loosen the two captive screws on the left and right sides. See Removing the Fan Tray Cover.

Figure 3-8 Removing the Fan Tray Cover
Identify the defective fan module.
If the amber (left) LED is on, the fan module is defective and should be replaced.

Note - If both green and amber indicators are on, then one of the two fans in the fan module is still operational. You should replace this fan module last if there is more than one fan module failure.
Remove the fan module.

Caution - Be careful to not damage the gaskets when you remove the fan module. Damaging the gaskets can disrupt proper airflow.

Using your thumb and forefinger, grasp the top handle of the fan module and lift the module up and out of the chassis. See Removing a Fan Module.

Figure 3-9 Removing a Fan Module
Figure Legend

1 Grab fan tray module by finger handle
2 Be careful not to damage the enclosure fan tray module gaskets
Install the new fan module:
1. Align the new fan module with the bay in the chassis.
2. Lower the fan tray into the bay until it comes into contact with the connector on the fan board.
3. Push down gently on the fan module until its connector is fully engaged.
  Once fully engaged, the amber LED on the fan tray may light momentarily.
Close the fan cover and tighten the retaining screws on the left and right sides of the cover.

To Replace the Front Indicator Board

The front indicator board supports the front panel power button and front panel indicator LEDs. This board also contains the ribbon cable that connects to the hard disk drive backplane. Be sure you have the tools necessary as described in 3.2 Tools and Supplies Needed.

Power off and unplug the array enclosure as described in Chapter 2, Configuring and Powering On the Sun Storage J4500 Array.

Caution - To power off the enclosure completely, you must disconnect the AC power cords from the back panel of the array enclosure. It takes a full 20 seconds with the AC power cords unplugged for internal power to be completely drained from the enclosure.

If the array enclosure is in a rack, slide it far enough out of the rack so that you can access the fan modules.
From the front of the enclosure, open the fan cover.
Using a No. 2 Phillips screwdriver, loosen the two captive screws on the left and right sides.
Remove fan tray 0 and fan tray 1.
Remove the hard disk drive access cover so that the fan cover opens more freely. See To Remove the Hard Disk Drive Access Cover.
Using a No. 2 Phillips screwdriver, loosen the two captive screws on the left and right sides.
Using a No. 1 Phillips screwdriver, remove the three screws (see 1 in Removing the Front Indicator Board Screws) securing the front indicator board to the chassis.
Figure 3-10 Removing the Front Indicator Board Screws
Detach the ribbon cable from the front indicator board, see Detaching the Ribbon Cable from the Hard Disk Backplane.
If you suspect that the ribbon cable is bad, remove the old ribbon cable from the hard disk drive backplane and use the new ribbon cable that comes with the new front indicator board. Make sure you route the ribbon cable through the cable securing clips to prevent damage to the cable.

Figure 3-11 Detaching the Ribbon Cable from the Hard Disk Backplane
Figure Legend

1 Ribbon cable connection to hard disk backplane
Install the new front indicator board:
1. Align the holes in the indicator board with the three screw holes in the inside-front of the chassis.
2. Using a No. 1 Phillips screwdriver, replace and tighten the two screws that secure the indicator board to the chassis.
3. Connect the ribbon cable to the connector on the hard disk drive backplane and to the connector on the front indicator board.
Replace fan module 0 and fan module 1.
Close the fan cover and, using a No. 2 Phillips screwdriver, tighten the two screws on the left and right sides.
Replace the hard disk drive access cover and, using a No. 2 Phillips screwdriver, tighten the two screws on the left and right sides. See To Replace the Hard Disk Drive Access Cover.

To Replace a Hard Disk Drive

This section describes how to remove and replace a hard disk drive. The J4500 array comes fully populated with 48 SATA drives installed. When replacing drives, note the following:

Replacement drives must be SATA, of the same capacity, and the same manufacturer as the drive being replaced. If is configured for multipathing, only supported drives may be used (for more on drives supported for multipath, see 4.4.5.4 Multipath Problems With Unsupported Drives).
Drives are a hot-pluggable CRU and can be replaced by anyone. Hot-pluggable means that the hard drive must be first brought offline by using a management software or operating system command; however, the array does not need to be powered off.
A single hard disk failure does not cause data loss if the hard disk is part of a RAID 1 (or higher) volume. The hard disk can be hot-plugged (but not hot-swapped). When a new hard disk is inserted, the contents are automatically rebuilt from the rest of the array with no need to reconfigure the RAID parameters. If the bad hard disk was configured as a hot spare, the new hard disk is automatically configured as a new hot spare.
Do not configure RAID volumes with drives of different capacities. This can cause unexpected operation or other problems. All drives in the array enclosure must be SATA and of the same capacity.
Each hard disk has a physical drive number, a map of the array hard disks is shown on the service label.
When using Linux hosts, if you add or remove array disks the host might hang or panic due to known Linux kernel issues. If you encounter this problem, a reboot of the host should resolve it.

Caution - To avoid overheating the array enclosure, do not leave a hard disk drive out for longer than 60 seconds at a time when the array power is on. Remove and replace only one hard disk drive at a time. Replace the hard disk drive access cover as soon as the service tasks are completed.

Remove the hard disk drive access cover as described in To Remove the Hard Disk Drive Access Cover.
Identify the defective hard disk by looking at the hard disk LEDs.
If the amber (middle) LED is on, the drive is faulty and should be replaced.
A failed drive should have already been taken offline by the system. If you want to remove a drive that has not failed (the amber LED is not lit), use the operating system or array management software to take the hard disk offline before you remove it. Not doing so could cause data loss or unexpected error messages.

Caution - Taking a disk offline that is part of a non-redundant logical drive causes the entire logical drive to fail and result in data loss.

If you are using an operating system command line, note that disks in the enclosure are typically identified in sequential order. Although the enclosure contains only 48 disks, your operating system may see a list of 51 devices; if this is the case, the first 4 addresses (0-3) represent the enclosure's four SAS expanders, the other 48 addresses (4-51) represent the 48 hard disks.
Once the drive has been taken off line, the blue ready-to-remove LED should turn on. This means the drive is ready to be removed and service action is allowed.
Remove the hard disk.
Lift the metal latch and remove the hard disk from the drive bay as shown in Removing a Hard Disk Drive, or on the service label.

Figure 3-12 Removing a Hard Disk Drive
Figure Legend

1 Identify desired hard disk
2 Unlatch hard disk
3 Lift and pull hard disk up and out of bay
Install the new hard disk of the same capacity as the one removed.
Push the hard disk into the bay until it stops, and make sure the drive is fully engaged with the connector on the hard disk backplane.
Make sure the metal handle is properly seated.
Replace the hard disk drive access cover. See To Replace the Hard Disk Drive Access Cover.
Configure the new hard disk.
Refer to your HBA or operating system documentation for information on adding a new hard disk.

Note - If the hard disk was previously configured as a RAID 1 (or higher) array, an automatic resynchronization is invoked and the contents are automatically rebuilt from the rest of the array with no need to reconfigure the RAID parameters. If the bad hard disk was configured as a spare, the new hard disk is automatically configured as a new spare.

To Replace the Power Distribution Board

This section describes how to remove and replace the power distribution board (PDB), which is also called the power backplane. Be sure you have the tools necessary as described in 3.2 Tools and Supplies Needed.

Power off the array enclosure as described in Chapter 2, Configuring and Powering On the Sun Storage J4500 Array.

Disconnect all cables from the enclosure.
Remove the system controller as described in To Replace the System Controller Module.
Remove all power supplies as described in To Replace a Power Supply.
From the back of the enclosure, remove the power supply cover.
Using a No. 1 Phillips screwdriver, remove the two screws on the power supply cover. Pull the cover toward you and lift. Some extra effort may be required to disengage the eight mushroom-head pins that secure the power supply cover to the chassis (see Removing the Power Supply Area Cover).

Figure 3-13 Removing the Power Supply Area Cover
Figure Legend

1 Power supply cover securing screws
Remove the rear chassis filler panel.
You must remove the rear chassis filler panel to get access to one of the screws that attaches the PDB to the chassis.
1. Push back the power supply swing door so you can access the area behind the rear filler panel.
2. Use a No. 2 Phillips screwdriver to remove the four screws that attach the rear chassis filler panel to the bay, as shown in Removing the Rear Chassis Filler Panel.
  Figure 3-14 Removing the Rear Chassis Filler Panel
Remove the PDB:
1. Remove the hard disk drive access cover as described in To Remove the Hard Disk Drive Access Cover. By removing the hard disk drive access cover, you will have more room to maneuver.
2. Use a No. 1 Phillips screwdriver to loosen the three captive screws that secure the PDB to the chassis. See Removing the Power Distribution Board.
  Figure 3-15 Removing the Power Distribution Board
  Figure Legend
  
  1 Power Distribution Board (PDB) securing screws
3. Put your fingers in the holes to pull the PDB up and then out of its keyed openings from the chassis standoffs. See Pulling Out the Power Distribution Board.
  Figure 3-16 Pulling Out the Power Distribution Board
Install the new PDB:
1. Align the new PDB so that the chassis standoffs protrude through its keyed openings, and then slide the PDB downward to lock it into place.
2. Push down on the edge of the board.
3. Use a No. 1 Phillips screwdriver to tighten the three captive screws that secure the PDB to the chassis. See Removing the Power Distribution Board.
4. Verify that the hard disk drive access cover intrusion switch is functioning correctly and is not bent during installation of the PDB. See To Replace the Hard Disk Drive Access Cover.
Replace the rear chassis filler panel.
Replace the power supply cover.
1. Align the mushroom-head pins with the indentations in the cover. This ensures that the intrusion switch is not blocked. For the locations of the mushroom-head pins, see Removing the Power Supply Area Cover.
2. Push down on the cover and then slide the cover forward into place.
3. Replace and tighten the two screws at the rear of the power supply cover.
Replace all power supplies:
1. Align the power supply with the empty bay in the chassis.
2. With the power supply handle in the down position, push the power supply into the bay. It will stop about three-quarters of the way in when it meets the connector on the PDB.
3. Next, continue to push in and lift the power supply handle up until the power supply fully engages with the PDB (indicated when the thumb-latch clicks into place). The power supply should be flush against the chassis. See To Replace a Power Supply.
Replace the system controller. See To Replace the System Controller Module.
Replace the hard disk drive access cover. See To Replace the Hard Disk Drive Access Cover.
Reconnect AC power cords to the power supplies. Make sue to use the power cord retaining clips to keep power cords secure.

To Replace a Power Supply

This section describes how to remove and replace a power supply.

The power supplies are fully redundant from 110 to 220 VAC; if one power supply fails, the other power supply will continue to operate.

Note - This component is a hot-swappable CRU and can be replaced by anyone. Hot-swappable means that you do not need to power off the array during replacement. However, you must unplug the power supply to be replaced or the entire system could shut down during removal.

The physical numbering of the two power supplies in the array enclosure is shown on the service label.

Identify which power supply you will replace. Each power supply has one fault LED that you can view from the rear of the array enclosure. If the LED is amber, the power supply is faulty and should be replaced.
Disconnect the AC power cord from the power supply that you are replacing.
The power supplies are hot-swappable, so you do not have to shut down the array or disconnect AC power from the other working power supply.

Note - The Service Action Required LEDs on the front panel and back panel blink when a power supply is unplugged. See 4.1 External Status LEDs for the LED locations and descriptions.
Remove the power supply.
1. Press down on the thumb latch at the center of the power supply. See Removing a Power Supply or the service label for an illustration.
  Figure 3-17 x86: Removing a Power Supply
2. While continuing to push on the latch, use the handle to pull the power supply from the chassis with one hand while supporting the power supply weight with the other hand.
Install the new power supply:
1. Align the power supply with the empty bay in the chassis.
2. With the power supply handle in the down position, push the power supply into the bay. It will stop about three-quarters of the way in when it meets the connector on the power distribution board.
3. Next, continue to push in and lift the power supply handle up until the power supply fully engages with the power distribution board (indicated when the thumb-latch clicks into place). The power supply should be flush against the chassis. See Replacing a Power Supply.
  Figure 3-18 x86: Replacing a Power Supply
Connect the AC power cord to the new power supply. Make sure you use the power cord retaining clips to keep the power cord secure.

To Replace the System Controller Module

The system controller (SC) consists of a sub-enclosure module and board that are removed as a unit from the back of the array enclosure. The system controller board contains the SAS expanders used to access the enclosure's 48 hard disk drives. The module is replaced as a unit—there are no replaceable parts inside.

Note the following before you begin:

If the array was configured for zoning (array storage divided among multiple initiators), ensure that the zoning configurations created with the Sun Comman Array Manager (version 6.4.1 at a minimum) have been exported to a file. Zoning configurations (including initiator-to-disk access and SAS domain passwords) are saved on the array's SAS expanders in the SC. You will need to import these configurations (per initiator and SAS domain) after you replace the SC. Refer to the chapters on zoning and multipathing in the Sun Storage J4500 Array System Overview (820-3163) for proper initiator-to-disk access configuration.
Be sure that you have first taken the array offline to prevent any host computer processes attempting to accessing it while the system controller is removed.
Be aware of SATA affiliations. When SATA drives are used, an affiliation (dedication) to the initiator (HBA port) is automatically created. This complies with the SATA protocol and is point-to-point in nature. If multiple initiators are attached to a single SAS fabric (either SAS A or B), the drive-to-initiator affiliation will be arbitrarily chosen which can create potential issues (such as disks or initiators not being seen). Refer to the chapters on zoning and multipathing in the Sun Storage J4500 Array System Overview (820-3163) for proper initiator-to-disk access configuration. Also refer to the Sun StorageTek Common Array Manager Release Notes for the version of CAM being used.

Caution - To prevent electrostatic discharge (ESD) damage to the components on the system controller, connect a ground strap between yourself and the chassis ground before proceeding. See Sun Storage J4500 Array Internal Components.

Disconnect the power cables from the array.

Caution - Although both power supplies should turn off when you remove the system controller, voltage could be present on the chassis connectors if either power supply did not shut down as expected. Thus, you must disconnect the power cords from the power supplies and wait 20 seconds to avoid any risk from inadvertent contact with those connectors.

Disconnect the SAS cable(s) connected to the system controller (SC) module.
You must label where your cables are connected as you disconnect them to ensure correct reconnection to a supported configuration.
Use a Phillips screwdriver to loosen the SC module handle lock screw. See Removing the SC Module.
Rotate the handle downward and pull the SC module from the chassis with one hand while supporting the system controller weight with the other hand.
Figure 3-19 x86: Removing the SC Module
Figure Legend

1 System Controller (SC) handle lock screw location
Slide out the SC module from the chassis.
Note that the SC module is connected inside the enclosure to the power distribution board, you may need to exert some pressure to disengage it.
To install the new SC module, first remove the plastic connector covers on the replacement SC module.

Caution - The module will not plug into the power distribution board with the connector covers on.
Align the SC module with the empty bay in the chassis.
Push the SC module into the bay until it stops (about three-quarters of the way in when it encounters the power distribution board connectors).
Use your thumbs to apply pressure to the upper right and left corners of the module and firmly push the SC module into place.
As the module engages the power distribution board, the module handle will lift into place.
Once the module is fully seated on the power distribution board, finish rotating the SC module handle up and into place (see Replacing the SC Module). Then tighten its securing screw.
Figure 3-20 Replacing the SC Module
Reattach any cables you previously unplugged from the SC module. Ensure that the cables are fully and properly seated.
Place the plastic connector covers you removed from the new SC module on to the connectors of the defective SC module for return to the factory.
If the array was configured for zoning or multipathing, you will need to re-establish the appropriate initiator-to-disk access configuration using the Sun Common Array Manager (version 6.4.1 at a minumum).
Detailed instructions for configuring zoning and multipathing for the array can be found in the Sun Storage J4500 Array System Overview (820-3163) and the Sun StorageTek Common Array Manager Release Notes for the version of CAM being used.

To Replace the Array Chassis

This section describes how to replace the array chassis, which includes the chassis, the hard disk drive backplane, and the front indicator board and ribbon cable.

Power off the array enclosure as described in Chapter 2, Configuring and Powering On the Sun Storage J4500 Array.
Unplug the power cords and SAS cables. Wait 20 seconds for the power supplies to power down.
Remove the system controller as described in To Replace the System Controller Module.
Remove the power supplies as described in To Replace a Power Supply.
Remove the fan modules as described in To Replace a Fan Module.
Label the hard disks so that you will know which slot to reinstall them in at the end of the procedure.
Note - When you remove the hard disks from their bays, you must return each hard disk to the equivalent bay in the new chassis. Use an adhesive note or another method to temporarily label the hard disks before you remove them.
Remove all hard disks from the drive bays as described in To Replace a Hard Disk Drive.
Remove old chassis from the rack as described in To Remove the Array Enclosure From the Rack.
Remove the rails attached to the old chassis so that you can put them on the new chassis.
Install the chassis side rails and slide the new enclosure chassis into the rack. Refer to the Sun X4500-J Slide Rail Installation Guide (820-1858) on the Sun documentation web site for more information.
Reinstall all hard disks to the new chassis as described in To Replace a Hard Disk Drive.
Note - You must return each hard disk to the bay from which it was removed. If the hard disks were previously configured for RAID (level 1 or higher), an automatic resynchronization should be invoked after the initial power on of the new enclosure to reconfigure the RAID parameters. Any hot spares should also be automatically reconfigured as hot spares.
Reinstall the power supplies into the new chassis as described in To Replace a Power Supply.
Reinstall the fan modules into the new chassis as described in To Replace a Fan Module.
Reinstall the SC module into the new chassis as described in To Replace the System Controller Module.

Skip Navigation Links
Exit Print View
	Sun Storage J4500 Array Service Manual