Service Handbook Model 745 HP Part No. A4964-90602 Edition E1199 Special Online Edition Printed in U.S.A.
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BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Hewlett-Packard shall not be liable for errors con- tained herein or for incidental or consequential damages in connec- tion with the furnishing, performance or use of this material.
Safety and Regulatory Statements Safety and Regulatory Statements Safety See the owner’s guide that came with your system for safety infor- mation. Regulatory Statements Emissions Regulations Federal Communications Commission (FCC) The Federal Communications Commission of the U.S. government regulates the radio frequency energy emanated by computing devices through published regulations.
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Safety and Regulatory Statements In the event that a third-party noncompliant I/O device is installed, the customer assumes all responsibility and liability arising there- from. Electrostatic Discharge (ESD) Precautions Electrostatic charges can damage the integrated circuits on printed circuit boards. To prevent such damage from occurring, observe the fol- lowing precautions during board unpacking and installation: •...
Contents Product Information The Model 745 Industrial Controller 1-3 Features 1-5 Typical External Devices 1-6 Physical Dimensions and Power Requirements 1-7 Board Computer Configurations 1-8 Cables 1-9 Operating System Overview 1-10 Manuals for System Information 1-11 HP-UX 1-11 HP VUE 1-11 HP CDE 1-11 Online Sources of Information 1-12 Audio 1-13...
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Contents Environmental/Installation/PM Overview 2-2 Environmental Specifications 2-3 Regulatory Requirements 2-4 Installation 2-5 Preventive Maintenance 2-6 Configuration Boot Console User Interface Features 3-2 Main Menu 3-3 Configuration Menu 3-4 Information Menu 3-5 Service Menu 3-6 Accessing the Boot Console Interface 3-7 Booting Your Workstation 3-9 Searching for Bootable Media 3-11 Restoring the Factory Default Configuration 3-12...
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Contents Displaying the Current Monitor Configuration 3-17 Setting the Monitor Type 3-18 Setting the Monitor Type at Power On 3-20 Using the Emergency Interactive Console Search 3-21 Displaying the Current Memory Configuration 3-23 Memory Information Example 3-23 Displaying the Status of the System I/O 3-25 Setting the Auto Boot and Auto Search and Auto Start Flags 3-26 Displaying and Setting the Security Mode 3-28...
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Introduction 5-2 Tools Required 5-2 Safety Precautions 5-2 New Parts 5-3 Exchange Parts 5-3 Local Hewlett-Packard Sales & Service Office 5-3 Replaceable Parts 5-4 Model 744 Board Computer Parts 5-7 Removing and Replacing the Model 744 Board Com- puter 5-9...
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Contents Removal 5-10 Replacement 5-10 Removing and Replacing RAM Cards 5-12 Preliminary Requirements 5-12 Removal 5-12 Replacement 5-13 Removing and Replacing the PMC Adapters 5-14 Preliminary Requirements 5-14 Removal and Replacement 5-14 Removing and Replacing the Front Panel 5-21 Preliminary Requirements 5-21 Removal and Replacement 5-22 Firmware ICs 5-23 Description 5-23...
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Contents Floppy Disk Drive 5-31 DDS Tape Drive 5-32 Hard Disk Drive Address Selection 5-33 Device Locations 5-33 Removing a Device from the Mass Storage Carriers 5-34 Installing a Device in a Mass Storage Carrier 5-35 EISA or PCI Backplane Replacement 5-40 Preliminary Requirements 5-40 Procedure 5-40 Power Supply Replacement 5-42...
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Contents Reference Documentation Service Documentation 7-2 System Installation and Getting Started Documentation Service Notes...
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Contents Figures Model 745 Front View 1-3 Model 745 Rear View 1-4 Board Computer Front Panel 1-4 Serial Number Information 1-14 Model 744 LED Location 4-7 Physical Memory Slots 4-31 Example Memory Address Worksheet 4-35 Memory Address Worksheet 4-37 Model 745 Exploded View 5-4 Model 744 Board Computer (Exploded View) 5-7 Locating the LAN ID 5-9 Model 744 Captive Screws 5-10...
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Contents Astec Power Supply Replacement 5-44 System Backplane Removal 5-46 Fuse Removal 5-47 Rear Fan Removal (Step 1) 5-48 RearFan Removal (Step 2) 5-49 Rear Fan Removal (Step 3) 5-49 Front Fans Removal 5-50 Model 745 Functional Block Diagram 6-2 Model 744 Block Diagram 6-3 Model 745 Power Distribution Diagram 6-4 xiii...
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Contents Tables Cabling 1-9 Environmental Information 2-3 Regulatory Information 2-4 System Paths 3-13 Mnemonic Style Notation 3-14 LED Indicators 4-8 Chassis Code Operating States 4-9 Chassis Codes 4-10 PIM Action Table 4-25 Processor Module Error (Data Cache Parity) 4-28 Multi-Bit Memory Parity Error 4-29 Logical Memory Slots 4-32 Memory Configuration Example 4-33 Memory Address Ranges 4-38...
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Product Information This chapter introduces the Model 745 Industrial Controller. Its purpose is to familiarize you with the system features, controls, and indicators. The major sections within this chapter are: • Features • Model 745 Physical Dimensions and Power Requirements •...
Model 744 board computer as the system controller, the Model 745 is exceptionally flexible and responsive, being based on Hewlett-Packard’s PA-RISC technology. Figure 1-1, Figure 1-2, and Figure 1-3 show a front view of the Model 745, a rear view, and the front panel of the board computer.
Product Information Features Features The Model 745 has the following general features: • Single-board computer processor: 132 MHz, or 165 MHZ • Input/Output: Onboard graphics, with optional 17-inch 1280x1024 monitor, or 19-inch 1280x1024 monitor 2 RS-232C ports AUI (LAN) port HP parallel port Audio I/O ports Speaker port...
Only products with Hewlett-Packard approved parts, accessories, peripherals, operating systems, and application programs are supported by Hewlett-Packard. Any product with other than HP approved hardware or software connected or installed must have the non- HP approved hardware and software removed by the customer before on-site repair is con-...
Product Information Physical Dimensions and Power Requirements Physical Dimensions and Power Requirements Physical dimensions: • Height: 177 mm (6.97 in.) - 4 EIA Units • Width: 425.45 mm (16.75 in.) • Depth: 412.77 mm (16.25 in.) Power requirements: • Input voltage: 100-240 Vac •...
Board Computer Configurations The Model 745 Industrial Controller incorporates the Model 744 single-board compter (SBC) as its processor. The Model 744 is a high-performance Precision Architecture board computer based on the Hewlett-Packard PA-RISC 7300LC technology. It contains the following key features: •...
Product Information Cables Cables Cables needed to connect to the ports of the Model 745 industrial controller are provided with the system. The high-density I/O connectors for the board computer require conversions to standard cabling. These cables are 75 cm (30 in.) long. See Table 1-1 for details of the cable included with the system.
Product Information Operating System Overview Operating System Overview The Model 744 uses the standard HP-UX 10.20 or later operating system, a highly versa- tile system for multitasking, running your application programs, and performing a variety of development tasks. Refer to HP-UX System Administration Tasks for detailed installa- tion and operation procedures for HP-UX.
Product Information Manuals for System Information Manuals for System Information HP-UX After you have completed the installation procedures in this book, you may consult the following sources for further information: • For HP-UX administration information, see HP-UX System Administration Tasks. •...
Product Information Online Sources of Information Online Sources of Information HP-UX is designed so that you can access many sources of information without leaving your system. Most of these information sources are accessible through the shell command line on a character terminal. •...
Product Information Audio Audio HP-UX includes audio software comprising an audio editor, Audio Application Program Interface (AAPI), and some sample programs. Audio output is available through the audio port on the front panel of the Model 745. For highest quality audio, an external headphone set or speaker is recommended.
Serial Number Information Support Support services and policies mentioned in this section are subject to change. Please con- sult your local Hewlett-Packard Sales and Service Office for the current support policies. Hardware Support Field Repair Philosophy Field Repair Philosophy for these products is assembly, or board level. When a failure occurs, the problem is diagnosed to the assembly having the failed part, that assembly is then replaced.
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On-Site Repair Customer Repair For Return to Hewlett-Packard Repair, customers return the product to their local HP Sales and Service Office, where an HP Bench Repair Engineer troubleshoots, and repairs the hardware to the assembly level. The defective assembly is replaced with a new or rebuilt assembly and the product is returned to the customer.
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Product Information Product Identification 1-16...
Environmental/Installation/PM Overview Overview This chapter lists the environmental specifications and regulatory requirements for the system. Installation and preventive maintenance information, if applicable, is also pro- vided.
Environmental/Installation/PM Environmental Specifications Environmental Specifications Table 2-1 lists the environmental specifications for this workstation. Table 2-1 Environmental Information Operating temperature 0° - 55° C (without mass storage) 5° - 40° C (with mass storage) Non-operating temperature -30° - 70° C Heat dissipation 2390 BTU, 600 Kcal/hr Humidity (non-condensing);...
Environmental/Installation/PM Regulatory Requirements Regulatory Requirements Table 2-2 lists the regulatory requirements for this workstation. Table 2-2 Regulatory Information Safety Specification: UL 1950, CSA 950M, IEC 950 Acoustics NS ISO 7779 Electromagnetic FCC, VCCI, Taiwan,Australia, Canada, and Certification European CE marks...
Environmental/Installation/PM Preventive Maintenance Preventive Maintenance The system unit requires no preventive maintenance. Some removable media storage devices require operator preventive maintenance. Refer to Model 745 Owner’s Guide for more information.
Configuration Boot Console User Interface Features Boot Console User Interface Features There are times when you want to interact directly with the hardware of your single board computer before it boots the operating system. Your 745 system provides a menu-driven boot console interface that allows you to perform special tasks, display information, and set certain system parameters, even if the operating system is unavailable.
Configuration Boot Console User Interface Features The boot console menus follow, showing the various tasks you can perform and the infor- mation available. The shortened version of all commands is indicated by the uppercase letters. Help is available for all menus and commands by using either help, he, or ? and the menu or command you want help on.
Configuration Boot Console User Interface Features Configuration Menu ------ Configuration Menu -------------------------------------------- Command Description ------- ----------- AUto [BOot|SEArch] [ON|OFF] Display or set specified auto flag BootID [<proc>] [<boot ID>] Display or modify processor boot ID BootINfo Display boot-related information BootTimer [0 - 200] Seconds allowed for boot attempt DEfault Set the system to predefined values...
Configuration Boot Console User Interface Features Information Menu ------ Information Menu ---------------------------------------------- Command Description ----------- ----------- Display all system information BootINfo Display boot-related information CAche Display cache information ChipRevisions Display revisions of VLSI and firmware COprocessor Display coprocessor information FwrVersion Display firmware version Dispay I/O interface information LanAddress...
Configuration Accessing the Boot Console Interface Accessing the Boot Console Interface To access the boot console interface, follow these steps: NOTE: This procedure should be done by a system administrator with root user privileges. Close any files and applications on your workstation. In a terminal window, enter the following command: reboot -h When the system has completely shut down, power off the system then power it back...
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Configuration Accessing the Boot Console Interface Press a key. You will then see the following message: Boot terminated The Main Menu of the boot console appears. ------ Main Menu ------------------------------------------ Command Description ------- ----------- BOot [PRI|ALT|<path>] Boot from specified path PAth [PRI|ALT|CON|KEY][<path>] Display or modify a path SEArch [DIsplay|IPL] [<path>]...
Configuration Booting Your Workstation Booting Your Workstation Usually, you start your workstation by turning it on and waiting for the operating system to boot automatically. However, you may not always want the usual sequence to occur. For example, you may want to start your workstation from an operating system that is stored on a device that is different from your usual boot device.
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Configuration Booting Your Workstation Answering quit (q) aborts the boot and returns you to the boot console handler. Answering no (n) continues the boot sequence with the device specified from the main menu prompt. Answering yes (y) causes the ISL to be loaded from the specified device. After a short time, the following prompt appears on your screen: ISL>...
Configuration Searching for Bootable Media Searching for Bootable Media To list devices that contain bootable media, follow the directions in “Accessing the Boot Console Interface” earlier in this chapter, and then type the following at the prompt: Main Menu: Enter command > search ipl The search command searches all buses.
Configuration Restoring the Factory Default Configuration Restoring the Factory Default Configuration To restore the factory default values in the EEPROM, follow the directions in “Accessing the Boot Console Interface” earlier in this chapter, and then type the following at the prompt to access the Configuration Menu: Main Menu: Enter command >...
Configuration Displaying and Setting Paths Displaying and Setting Paths A path is the hardware address of a device that is attached to the I/O system of your work- station. The path command sets the system paths shown in Table 3-1. The path command sets and displays the hardware address of a specified device attached to the I/O bus of your workstation.
Configuration Displaying and Setting Paths The paths are displayed in Mnemonic Style Notation, as shown in Table 3-2. Table 3-2 Mnemonic Style Notation I/O Type Specification Format Built-in SCSI sescsi.scsi_address.logical_unit_number Built-in LAN lan.server_address.init_retries.io_retries PCI Slot pcin PMC Slot pmcn On-board Graphics graphics(0) PS/2 Keyboard RS232(A)
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Configuration Displaying and Setting Paths To display the current setting for a particular system path, follow the directions in “Accessing the Boot Console Interface” earlier in this chapter, and then type the following at the prompt: Main Menu: Enter command > path path_type where path_type is one of the path types listed in Table 3-1.
Configuration Displaying and Setting the Monitor Type Displaying and Setting the Monitor Type Your system ships from the factory preset to use a monitor with a specific resolution and frequency. If you replace your workstation’s monitor with a different type of monitor, you must reconfigure your workstation to support the new monitor.
Configuration Displaying and Setting the Monitor Type Displaying the Current Monitor Configuration To display the current monitor configuration for your system from the Configuration Menu of the boot console interface, follow the directions in “Accessing the Boot Console Interface” earlier in this chapter. Once you are in the Boot Console Interface Main Menu, type: Main Menu: Enter command >...
Configuration Displaying and Setting the Monitor Type Setting the Monitor Type You can set the monitor type for a graphics adapter from the configuration menu by enter- ing the following: Configuration Menu: Enter command > monitor graphics(0) tt - or - Configuration Menu: Enter command >...
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Configuration Displaying and Setting the Monitor Type To set the monitor type for graphics(0) to monitor type 2 you would enter the following; Configuration Menu: Enter command > monitor graphics(0) 2 This will take effect on the next reboot. MONITOR INFORMATION Path Slot Head...
Configuration Displaying and Setting the Monitor Type Setting the Monitor Type at Power On If you replace your workstation’s monitor with a different monitor type, and do not set the workstation’s graphics parameters by using the monitor command before doing so, you need to perform the following steps at power on: If your keyboard connects to the PS/2 connector on your system, wait 2 seconds after the Num Lock light flashes near the end of the boot sequence, then press...
Configuration Displaying and Setting the Monitor Type Using the Emergency Interactive Console Search If the system console is set to a device that is not installed in the system, you can use the emergency interactive console search to set the console to one of the terminal devices that is currently connected.
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Configuration Displaying and Setting the Monitor Type To advance all graphics adapter monitors to the next resolution, press the <Tab> key one time and wait five seconds for all monitor types to change. Do not hold down the <Tab> key or press it multiple times as this will cause the monitor types to advance for each press of the <Tab>...
Configuration Displaying the Current Memory Configuration Displaying the Current Memory Configuration The memory command shows the memory configuration table. To display the current memory configuration for your system, from the Information Menu of the boot console interface, follow the directions in “Accessing the Boot Console Inter- face”...
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Configuration Displaying the Current Memory Configuration The following listing is a sample memory configuration table when memory modules are properly installed and configured: MEMORY INFORMATION MEMORY STATUS TABLE Slot Size Status ---------------- 64MB Configured 32MB Configured 64MB Configured --------- TOTAL 160MB If the power-on selftest detects a defective or damaged memory card, using the memory command (from the Information Menu prompt) displays the following information:...
Configuration Displaying the Status of the System I/O Displaying the Status of the System I/O The IO command is available from the information menu. It lets you identify all built-in I/ O devices and optional I/O devices installed in the option slots. To use the IO command from the Information Menu of the boot console interface, type: Information Menu: Enter command >...
Configuration Setting the Auto Boot and Auto Search and Auto Start Flags Setting the Auto Boot and Auto Search and Auto Start Flags The auto boot, auto search, and auto start flags are variables stored in your worksta- tion’s nonvolatile memory. (Nonvolatile memory retains its contents even after power is turned off.) If you reset these flags to a new value, the change takes effect the next time you reboot the workstation.
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Configuration Setting the Auto Boot and Auto Search and Auto Start Flags Autosearch searches for devices in the following order: Primary Boot Path Alternate Boot Path Built-in Single-Ended SCSI Devices Built-in LAN bootp servers 3-27...
Configuration Displaying and Setting the Security Mode Displaying and Setting the Security Mode The SECure flag is a variable stored in non-volatile memory. (Non-volatile memory retains its contents even after power is turned off.) If you reset this flag to a new value, the change takes effect the next time you reboot the board computer.
Configuration Displaying and Setting the Fastboot Mode Displaying and Setting the Fastboot Mode When fastboot is enabled (set to on), your workstation does a quick check of the memory and skips I/O interface testing during its power-on self tests. This enables your worksta- tion to complete its boot process more quickly.
Configuration Displaying the LAN Station Address Displaying the LAN Station Address It is sometimes necessary to supply the LAN station address of your workstation to other users. For example, if your workstation is to become a member of a cluster, the cluster administrator needs to know your LAN station address in order to add your workstation to the cluster.
Configuration Displaying System Information Displaying System Information The all command allows you to display the system’s processor revision and speed, cache size, memory size, flag settings, and the boot and console paths. To display system infor- mation from the Information Menu, type the following at the prompt: Information Menu: Enter command >...
Configuration Displaying PIM Information Displaying PIM Information The pim command allows you to display the most recent PIM information for the speci- fied fault type. To display PIM information for a specific fault, type the following at the Service Menu prompt: Service Menu: Enter command >...
Configuration Power Budgeting Power Budgeting The power supply accomodates the needs of all devices and options available for the Model 745 (within specifications for the options and applicable interface specifications). No power budgeting is required. 3-33...
Troubleshooting This chapter provides information about isolating a failing/failed component in a Model 744 board computer through the use of diagnostic tests and troubleshooting techniques. A failed component is traced to the level of the Field Replaceable Unit (FRU) and the FRU is replaced to correct a problem.
Troubleshooting Dealing with a Boot Failure Dealing with a Boot Failure To start this workstation from an operating system stored on a device different from the usual boot device, to boot from a different disk, or to boot from another type of device (such as a DDS tape drive), see the following situations and examples that use the Boot Console Interface.
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Troubleshooting Dealing with a Boot Failure Answering yes (y) causes the ISL to be loaded from the specified device. After a short time, the following prompt appears on the screen: ISL> ISL is the program that actually controls the loading of the operating system. By interacting with ISL, you can choose to load an alternate version of the HP-UX operating system.
Troubleshooting Dealing with a Boot Failure Searching for Bootable Media To list all devices that may contain bootable media, go to the Main Menu of the Boot Con- sole Interface and then type the following at the prompt: Main Menu: Enter command > search ipl The search may turn up more devices than there are lines on the display.
Troubleshooting Dealing with a Boot Failure Boot Command Notations The boot command supports the following two notations: • Mnemonic • Path number Type help path or help boot for more information on the boot path parameters. Here are examples of mnemonic notation: •...
Troubleshooting Dealing with a Boot Failure ISL Environment ISL provides the means to load the operating system. ISL also provides an offline platform to execute diagnostic and utility programs contained in the LIF volume on the boot device when the operating system is not loaded. The ISL program is the first program loaded into main memory from an external media (LAN, disk, or tape) and launched by the initial program loader (IPL) routine from the Boot Administration environment.
Troubleshooting Firmware Selftest Failures Firmware Selftest Failures Two methods are used by the firmware to provide diagnostic information: the LEDs on the board computer’s front panel and ASCII encoded chassis codes which are output through the RS-232 (A) port. Interpreting the Front Panel LEDs The Model 744 provides two LEDs, located to the left and right of the reset switch, as shown in Figure 4-1.
Troubleshooting Firmware Selftest Failures Table 4-1 provides information on interpreting the system status from the LEDs. Table 4-1 LED Indicators SYSFAIL POWER Meaning Possible Solution (Red) (Green) No Power Check for board seating in chassis. 2Hz Flash Normal Power-on/ If the system never proceeds selftest past this point, either the con- sole path is not set or there is...
Troubleshooting Firmware Selftest Failures Interpreting the Diagnostic Chassis Codes The chassis codes convey the state of the system. Each chassis code consists of two fields, the general operating state of the system and a four-digit hexadecimal (hex) status code indicating the specific system hardware or software component as follows: xxxx nnnn Where xxxx is an ASCII string indicating the operating state, and nnnn is the hexadecimal status code.
Troubleshooting Firmware Selftest Failures The following table provides information on interpreting the diagnostic chassis codes to troubleshoot the system to the FRU (Field Replaceable Unit) level. Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range 1001-101F Unknown Unexpected Interrupt Note what chassis codes pre- cede this fault condition, then remove or replace the...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range 10FF Self-test failure Replace the single board 744 SBC computer. 2000-20FF CPU built-in level-1 Replace the single board 744 SBC cache self-tests and init computer. 3000--30FF PDH self-test, init, and Replace the single board 744 SBC...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range 503F HPMC due to bus error 504F Processor memory access exceeded bounds of configured These conditions result in an memory space HPMC. Refer to the section Unknown “Dealing with HPMC 505F...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range 80F7 Various ENTRY_IO procedure for the current module returned a failure status 80F8 Various Device class for cur- Confirm that the paths are rent boot device is set correctly, cables are cor- invalid rectly connected, and power...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range 9000 Various Device specified by console path not found 9001 Various Could not find a con- sole device A008 Various Could not locate a boot Confirm that the paths are device set correctly, cables are cor- rectly connected, and power...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range C400 Retrieving the Stable Store console path C440 Initializing the Stable Store console path C500 Retrieving the primary boot path C540 Initializing the pri- mary boot path C580 Loading IPL from the primary boot path...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range C5FF Branching to IPL from the primary boot device C600 Retrieving default con- sole path C640 Initialize default con- sole path C641 Initializing current graphics device C64F Retrying bad monitor type...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range C7F0 An error occurred read- ing IPL from alternate boot device C7F1 LIF address is zero or not 2K byte aligned on alternate boot device C7F2 LIF file not present on alternate boot device File system may be corrupt...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range CB05 Invalid checksum for OS_TOC code CB0A Previous TOC PIM logged CB0B Branching to OS_TOC handler CB0C Branch to OS_TOC failed CB9A HPMC PIM overwrit- CBF0 HPMC handling initi- ated CBF1...
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range CBFB Branching to the OS HPMC handler CBFC Failed branch to the OS HPMC handler Refer to the section Dealing with HPMC (Uncorrectable CBFE HPMC interrupted a Error) later in this chapter.
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Troubleshooting Firmware Selftest Failures Table 4-3 Chassis Codes Chassis Description Possible Solution Code Range CDFF System map initializa- tion complete a. SBC (Single Board Computer) To get additional information about failures, from the boot console interface, use the pim and Chassis Code commands from the Service Menu. 4-20...
Troubleshooting Running ODE-Based Diagnostics Running ODE-Based Diagnostics The Offline Diagnostic Environment (ODE) consists of diagnostic modules for testing and verifying system operation. ODE provides all the necessary functions for the user to load specified tests and interact with those tests. ODE is an ISL utility.
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Troubleshooting Running ODE-Based Diagnostics • mapper - identifies the configuration of HPPA systems. It displays path, identification, and revision information of I/O components, con- figuration of memory controllers, processors, co-processors, cache, and TLB, as well as processor board component revisions and values of various HPPA system identifiers, revisions, and capabilities.
Troubleshooting Running System Verification Tests Running System Verification Tests HP-UX uses an online diagnostics product called the Support Tools Manager that allows system operation verification. HP-RT does not support online diagnostics. Three interfaces are available with the Support Tools Manager: a command line interface (accessed through the cstm command), a menu-driven interface (accessed through the mstm command), and the graphical user interface (accessed through the xstm command).
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Troubleshooting Running System Verification Tests To access the Support Tools Manager, you must be logged in as “root” or “superuser”, and perform the following steps: In a terminal window, type the following at the # prompt to invoke the command line interface: # cstm The following message appears:...
Troubleshooting Dealing with HPMC (Uncorrectable Error) Dealing with HPMC (Uncorrectable Error) The power-on sequence follows this path: Power-on -> Selftest -> Console Path -> Boot Admin Mode -> Boot Path -> ISL Mode -> Operating System Mode When the hardware detects an unrecoverable (HPMC) error in the Operating System envi- ronment, an error message, referred to as a Kernel Tombstone is displayed on the monitor.
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Troubleshooting Dealing with HPMC (Uncorrectable Error) Table 4-4 PIM Action Table Cache System Check Bus Check Check Responder Action Type Word Word Word Word 0x20000000 0x00310007 0xF0280000 Replace PCMCIA 0xF029FFFF adapter. If problem persists replace CPU board. 0x20000000 0x00310007 0xF0300000 Replace CPU 0xF031FFFF board.
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Troubleshooting Dealing with HPMC (Uncorrectable Error) Table 4-4 PIM Action Table Cache System Check Bus Check Check Responder Action Type Word Word Word Word 0x20000000 0x00310007 0xFC000000 Replace EISA tray, 0xFFBFFFFF if present, otherwise check VME system configuration, and/ or replace CPU board.
Troubleshooting Dealing with HPMC (Uncorrectable Error) HPMC Caused by a Data Cache Parity Error For example, an HPMC interruption is forced when a data cache parity error is detected during a load instruction to the memory address space or during a data cache flush opera- tion.
Troubleshooting Dealing with HPMC (Uncorrectable Error) HPMC Caused by a Multi-Bit Memory Parity Error An HPMC interruption is forced when a multi-bit memory parity error is detected during a “DMA read” operation or fetching an I/D cache line (32 bytes). Table 4-6 shows an example of the HPMC error information retrieved from Stable Storage by the PIM command during the Boot Administration environment.
Troubleshooting Dealing with HPMC (Uncorrectable Error) Determining the Faulty Memory Card Memory is configured in a contiguous fashion starting at a base hexadecimal address of 0x00000000 to a maximum of 0x3FFFFFFF (1024MB). Memory is installed on the Model 744 in a single stack of up to four memory cards of 16MB, 32MB, 64MB, 128MB or 256MB capacity.
Troubleshooting Dealing with HPMC (Uncorrectable Error) NOTE: When mixing memory cards of different capacities, 128MB and 256MB cards must always be in the lowest numbered physical slots. Physical Slot 3 Physical Slot 2 Physical Slot 1 Physical Slot 0 Figure 4-2 Physical Memory Slots 4-31...
Troubleshooting Dealing with HPMC (Uncorrectable Error) During the boot process, when the system sizes the memory to create a memory map, the memory slots are divided into eight logical slots. For better understanding, they will be referred to from herein as logical slots 0 through 7. The system maps two logical slots to each physical slot as shown in Table 4-7.
Troubleshooting Dealing with HPMC (Uncorrectable Error) After the 256MB cards are sized, the 128 and 64MB cards are sized in a similar manner. Then the sizing progresses to the 16MB segment of memory in the lowest numbered logi- cal slot, then the 16MB segment in the next highest numbered logical slot, and so on, until all of the memory has been mapped.
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Troubleshooting Dealing with HPMC (Uncorrectable Error) A worksheet is needed to determine the address ranges associated with each of the logical slots. In the example in Figure 4-3 below, the memory configuration example shown in Table 4-8 has been used. In this example, we first determine the memory cards that are installed in each physical slot.
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Troubleshooting Dealing with HPMC (Uncorrectable Error) Perform the following steps to fill out the worksheet: Determine the memory capacity of each memory card in the physical slots and circle the corresponding number in the second column of Figure 4-4. For 32MB cards, circle a 16 for each of the two logical slots associated with the physical slot.
Field Replaceable Units Introduction Introduction This chapter contains the procedures to replace assemblies in the Model 745 chassis com- ponents (such as the board computer module, EISA/PCI module, mass storage module, power supply and chassis mounted hardware). Tools Required All field replaceable parts can be accessed with these tools: Grounding wrist strap.
Field Replaceable Units Introduction Replaceable Parts Figure 5-1 shows an exploded view of the Model 745 industrial system. Figure 5-1 Model 745 Exploded View...
Field Replaceable Units Introduction Table 5-1 is a chassis parts list. Table 5-1 Model 745 Chassis Parts List Non-Exchange Description Part Number A4964-62008 Chassis Assembly A4964-66006 System Backplane A4505-66001 PCI Interface Board A4964-66003 PCI Backplane A4309-66001 EISA Interface Board A4964-66004 EISA Backplane A2636-00004 Slot 3 Cover Plate...
Field Replaceable Units Introduction Table 5-2 is a mass storage parts list. Table 5-2 Mass Storage Parts List Exchange Non-Exchange Description Part Number Part Number A2084-69005 3.5 in. Flexible Disk Drive A1658-69012 4GB Hard Disk Drive, SE C1539-69201 DDS-2 Tape Drive A1658-60015 CD-ROM Drive A4964-62002...
Field Replaceable Units Model 744 Board Computer Parts Model 744 Board Computer Parts Consult the appropriate model Service Handbook for parts and part numbers. Figure 5-2 lists the major pieces of the Model 744 assembly. Table 5-3 lists the part num- bers of the exchange parts and Table 5-3 lists the part numbers of the non-exchange parts of the Model 744.
Field Replaceable Units Model 744 Board Computer Parts Table 5-3 Replaceable Parts Exchange Non- Callout Part Exchange Description Number Number Part Number A4500-69001 System board: 132 MHz (with on-board graphics) A4500-69006 System board: 165 MHz (with on-board graphics) A4502-69001 32 MB RAM card A4503-69001 64 MB RAM card A4500-69005...
Field Replaceable Units Removing and Replacing the Model 744 Board Computer Removing and Replacing the Model 744 Board Computer This section provides step-by-step instructions for removal and replacement of a single slot and dual slot 744 board computer. Preliminary Requirements If you are replacing a defective 744 board computer with a new one, you must determine the LAN ID of the existing 744 board computer before replacing it.
Model 744 Captive Screws Replacement After removing all the accessories, place them on the new/exchange board and return the failed board to Hewlett-Packard. Install the new Model 744 board computer in the chassis and reconnect any cables or peripherals. 5-10...
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Field Replaceable Units Removing and Replacing the Model 744 Board Computer When you power on the new Model 744 for the first time, you need to enter the LAN ID that you recorded from the defective board in the Removing and Replacing the Model 744 Board Computer section earlier in this chapter.
Field Replaceable Units Removing and Replacing RAM Cards Removing and Replacing RAM Cards This section provides step-by-step instructions for removing RAM cards from your Model 744. Preliminary Requirements Before you remove a RAM card: Remove the Model 744 from its card cage. (See Removing and Replacing the Model 744 Board Computer, earlier in this chapter.) Removal Follow these steps to remove RAM cards:...
Field Replaceable Units Removing and Replacing RAM Cards 2 Pull the RAM card up and off the RAM stack or board computer. 3 Repeat the procedure for multiple RAM cards. The spacers between cards act as retaining screws for the card below; remove them to access the card. Replacement To replace a card, remove the old card according to the removal procedure.
Field Replaceable Units Removing and Replacing the PMC Adapters Removing and Replacing the PMC Adapters This section provides step-by-step instructions for replacing the adapter (expansion kit) fixture in your Model 744. Preliminary Requirements Before removing the adapter (Expansion Kit) fixture from your Model 744, remove the Model 744 from it’s card cage.
Field Replaceable Units Removing and Replacing the PMC Adapters Figure 5-8 Removing the PMC Expansion Adapter To remove a PMC card from the expansion adapter, remove the four screws from the bottom of the expansion adapter and separate the PMC card from the expansion adapt- er, as shown in Figure 5-9.
Field Replaceable Units Removing and Replacing the PMC Adapters Figure 5-9 Removing a PMC card from the Expansion Adapter Remove the bridge adapter’s four front panel screws, as shown in Figure 5-10. Remove the bridge adapter’s four backplane connector screws, as shown in Figure 5- Separate the bridge adapter from the board computer.
Field Replaceable Units Removing and Replacing the PMC Adapters Figure 5-11 Removing a PMC card from the Bridge Adapter 10 To remove a PMC card from the bridge adapter, remove the four screws from the bot- tom of the bridge adapter and separate the PMC card from the bridge adapter, as shown in Figure 5-11.
Field Replaceable Units Removing and Replacing the Front Panel Removing and Replacing the Front Panel This section provides step-by-step instructions for removing the front panel of your Model 744. Preliminary Requirements Perform the following steps before removing the front panel: Remove the Model 744 from its card cage.
Field Replaceable Units Removing and Replacing the Front Panel Removal and Replacement Follow these steps to remove the front panel: Remove the interface port jack screws (There are two around each port - SCSI, video, and so forth) using the appropriate 3mm (0.125-inch) or 4mm (0.160-inch) nutdriver. The port jack screws are shown in Figure 5-12.
Field Replaceable Units Firmware ICs Firmware ICs This section provides information on the Model 744 firmware ICs. Description The ICs in the Model 744 are designated: UC1, UD1 an UE1. They perform booting func- tions, input/output and provide non-volatile stable storage. Figure 5-13 744 ICs UE1 is non-volatile stable storage.
Field Replaceable Units Removing and Replacing the Real-Time Clock Bat- tery Removing and Replacing the Real-Time Clock Battery This section provides step-by-step instructions for removing and replacing the real-time clock (RTC) in your Model 744. Preliminary Requirements WARNING: Lithium batteries may explode if mistreated. Replace battery with only HP Part No.
Removing the Top Cover, Front Bezel, and Mid-Tray Removing the Top Cover, Front Bezel, and Mid-Tray Removing the top cover is necessary to gain access to internal components such as: • mass storage devices • PCI or EISA cards Removing the front bezel is necessary to gain access to internal components such as: •...
Replacing Mass Storage Devices Replacing Mass Storage Devices NOTE: All Installation procedures are the reverse of removal in this section. Procedure Remove the system top cover using the procedure earlier in this chapter. If replacing a device go to Selecting Device Address. If the only action is to remove a device go to Mass Storage Device Removal.
Replacing Mass Storage Devices Hard Disk Drive Address Selection All replacement hard disk drives are shipped with jumper/configuration documentation. Please refer to the documentation shipped with the replacement disk drive for jumper set- tings and any applicable software patch dependencies. Device Locations Figure 5-20 shows the factory default device locations for the Model 745 industrial sys- tem.
Replacing Mass Storage Devices Removing a Device from the Mass Storage Carriers CAUTION: Hard disk drives are vulnerable to physical shock. Dropping a hard disk drive from even a small height will damage its heads and platters. Always handle hard disk drives with extreme caution. Do not place a hard disk drive upside down on any surface.
Replacing Mass Storage Devices If necessary, remove the disk adapter brackets used to mount a 3.5-inch device in a 5.25-inch bay. Installing a Device in a Mass Storage Carrier Remove the new device from its shipping box Ensure that the hardware SCSI bus address selected on the device is not already used by the system.
Replacing Mass Storage Devices 5.25-inch to 3.5-inch adapter brackets Figure 5-23 Installing the 3.5-inch adapter brackets Filler panels Figure 5-24 3.5-Inch Hard Disk Installation with Filler Panel 5-37...
EISA or PCI Backplane Replacement EISA or PCI Backplane Replacement Preliminary Requirements Remove the top cover using the procedure earlier in this chapter. Remove the front bezel using the procedure earlier in this chapter. Remove the mid-tray using the procedure earlier in this chapter. Procedure Remove any EISA or PCI cards from the chassis.
Power Supply Replacement Power Supply Replacement Two power supplies are used in the Model 745 - a Cherokee and an Astek Preliminary Requirements Remove the top cover using the procedure earlier in this chapter. Remove the front bezel using the procedure earlier in this chapter. Remove the mid-tray using the procedure earlier in this chapter.
System Backplane Replacement System Backplane Replacement Preliminary Requirements Remove the top cover using the procedure earlier in this chapter. Remove the front bezel using the procedure earlier in this chapter. Remove the mid-tray using the procedure earlier in this chapter. Remove the power supply using the procedure earlier in this chapter.
System Backplane Replacement System Backplane Removal Disconnect all wire harness from the backplane Remove the Model 744 board compter and PMC bridge and expander baords, if present, from the chassis Remove the system backplane cover plate. See Figure 5-31. Remove the screws that secure the backplane to the chassis, and remove the backplane. Figure 5-31 System Backplane Removal 5-46...
Fuse Replacement Fuse Replacement Preliminary Requirements Remove the top cover using the procedure earlier in this chapter. Remove the front bezel using the procedure earlier in this chapter. Remove the mid-tray using the procedure earlier in this chapter. See Figure 5-32. Figure 5-32 Fuse Removal 5-47...
Rear Fan Replacement Rear Fan Replacement Remove fan guard (see Figure 5-33), disconnect the fan cable from the fan, and push the fan upwards. Figure 5-33 Rear Fan Removal (Step 1) 5-48...
Rear Fan Replacement Push the bottom of the fan inwards, moving the top of the fan down. See Figure 5-34. Pull the fan out through the rear panel. See Figure 5-35 Figure 5-34 RearFan Removal (Step 2) Figure 5-35 Rear Fan Removal (Step 3) 5-49...
Front Fans Replacement Front Fans Replacement Preliminary Requirements Remove the top cover using the procedure earlier in this chapter. Remove the front bezel using the procedure earlier in this chapter. Disconnect the fan cables from the fans. See Figure 5-36. Figure 5-36 Front Fans Removal 5-50...
Diagrams Functional Description of Model 745 Chassis Functional Description of Model 745 Chassis The Model 745 chassis provides the following: • One 400-Watt power supply. • Four slot EISA backplane or four slot PCI backplane • Five Internal Mass Storage Device mounting and electrical capability. Figure 6-3 shows the Model 745 functional block diagram.
Diagrams Functional Description of Model 745 Chassis Figure 6-3 shows the Model 745 power distribution diagram. Figure 6-3 Model 745 Power Distribution Diagram...
Reference Documentation Introduction Introduction Information in this chapter should help you in various situations. The references include part numbers of many hardware documents relating to this system. Service Documentation Table 7-1 Related Service Documentation Manual Title Part Number HP Model 744 Board Computer Service Handbook A4511-90603 Model 745 Technical Reference Manual for OEMs A4964-90063...
Reference Documentation Introduction Table 7-2 Diagnostic Documentatio Manual Title Part Number Support Tools Manager User’s Manual; HP 9000 Series 700 5961-1612 and 800 HP Apollo 9000 Series 700 Diagnostics Manual, Volume 1 09740-90041 HP Apollo 9000 Series 700 Diagnostics Manual, Volume 2 09740-90043 HP Apollo 9000 Series 700 Support Tape/CD-ROM User’s B2380-90000...
Reference Documentation System Installation and Getting Started Documen- tation System Installation and Getting Started Documentation Table 7-3 System Installation and Getting Started Documentation Manual Title Part Number Model 745 Industrial Controller Owner’s Guide A4964-90605 Model 744 Board Computer Owner’s Guide A4511-90606...
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Index path 3-13 accessories 1-8 information pim 3-32 adapter cables 1-9 online 1-12 reset 3-12 altitude 2-3 system 1-11 search 3-11 audio 1-13 Initial System Loader. See ISL conversion cables 1-9 auto boot 3-26 installation 2-5 changing state 3-26 auto search 3-26 environment 4-6 DDS tape drive changing state 3-26...
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Index ODE-based diagnostics 4-21 SCSI offline diagnostics environ- default ID 5-29 ment (ODE) 4-21 hard disk drives 5-33 operating system 1-10 serial number 1-14 HP-RT 1-10 service documentation 7-2 HP-UX 1-10 service notes 8-2 overview 1-10 stable storage 4-4 operating temperature 2-3 storage stable 4-4 support 1-14...