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Part Number 104380-101 Released 09/2005 N e o - 8 0 4 2 c Overland NEO 8000 Remove & Replace Instructions Z-Axis Robotics Retrofit

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Part Number 104380-101Released 09/2005

Neo

-804

2c

Overland NEO 8000

Rem

ove

& R

epla

ce In

stru

ctio

ns

Z-Axis Robotics Retrofit

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ii Part Number 104380-101 09/2005

Proprietary Notice

All information contained in or disclosed by this document is considered proprietary by Overland Storage. By accepting this material, the recipient agrees that this material and the information contained therein are held in confidence and in trust and will not be used, reproduced in whole or in part, nor its contents revealed to others, except to meet the purpose for which it was delivered. It is understood that no right is conveyed to reproduce or have reproduced any item herein disclosed without express permission from Overland Storage. Overland Storage provides this manual as is, without warranty of any kind, either expressed or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Overland Storage may make improvements or changes in the products or programs described in this manual at any time. These changes will be incorporated in new editions of this publication.

Overland Storage assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of this manual, nor for any problem that might arise from the use of the information in this manual.

Overland products are covered by one or more of the following patents registered with the USPTO: 5,870,245; 6,328,766; 6,353,581; 6,496,325.

Worldwide Headquarters Overland Storage, Inc.4820 Overland AvenueSan Diego, CA 92123Toll Free: (800) 729-8725Tel: (858) 571-5555Fax: (858) 571-3664

Sales Tel: (858) 571-5555Fax: (858) 571-3664E-mail: [email protected]

Technical Support Tel: (858) 571-5555Fax: (858) 571-3664Toll Free: (877) 654-3429E-mail: [email protected]

Overland Storage, EMEA Overland House, Ashville WayWokingham, BerkshireRG41 2PL, EnglandTel: +44 (0) 118-9898000Fax: +44 (0) 118-9891897www.overlandstorage.com

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Part Number 104380-101 09/2005 iii

Preface

About this GuideThis Remove & Replace guide provides instructions and information required for the removal and replacement of the Overland Storage Z-Axis Belt Drive Assemblies (BDA) in a NEO 8000™ Library that have been identified as possibly having an incorrect pulley installed.

NOTE: This applies only to certain libraries built between December 2004 and May 2005.

ConventionsThis user guide exercises several typographical conventions.

Convention Description & Usage

Boldface Words in boldface indicate items to select such as menu items or command buttons.

Ctrl-Alt-r This type of format details the keys you press simultaneously. In this example, hold down the Ctrl and Alt keys and press the r key.

NOTE A Note indicates neutral or positive information that emphasizes or supplements important points of the main text. A note supplies information that may apply only in special cases—for example, memory limitations or details that apply to specific versions of a program.

IMPORTANT An Important note is a type of note that provides information essential to the completion of a task or that can impact the product and its function. Users can disregard information in a regular note and still complete a task, but they should not disregard an important note.

CAUTION A Caution contains information that the user needs to know to avoid damaging or permanently deleting data or causing physical damage to the hardware or system.

WARNING A Warning contains information essential to people’s safety. It advises users that failure to take or avoid a specific action could result in physical harm to the user or hardware.

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iv Part Number 104380-101 09/2005

Preface

Overland Storage Technical SupportFor more assistance, search for help at:

http://support.overlandstorage.com/

Our Overland Storage Technical Support staff is also available to assist you by phone at:

1.877.654.3429 (Toll-free and active only in US and Canada)1.858.571.5555 x5 (Worldwide)

On normal business days 6 AM through 5 PM (California time) excluding Overland holidays. At all other times we will respond to technical support calls within 4 hours.

Technical support for our European customers is available as well from our United Kingdom office at:

+44 (0) 118-98980509:00 am to 5:00 pm (GMT)Monday through Friday

You can e-mail our technical support staff at [email protected].

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Part Number 104380-101 09/2005 v

Table of Contents

PrefaceAbout this Guide ..................................................................................................................... iiiConventions ............................................................................................................................. iiiOverland Storage Technical Support ...................................................................................iv

Chapter 1 - IntroductionReplacement Process Overview ........................................................................................ 1-1

Required Tools ................................................................................................................. 1-2Electrostatic Discharge Information ................................................................................... 1-2Unpacking the Retrofit Kit .................................................................................................... 1-2

Chapter 2 - Prepare the Library for Internal AccessRemoval of Media Drawers ................................................................................................ 2-1Power Down the Library ...................................................................................................... 2-2Remove Panels for Access .................................................................................................. 2-2

Front Panel Assembly ..................................................................................................... 2-2Rear Access Panels ........................................................................................................ 2-4

Chapter 3 - Replace the Front BDARemove the Front BDA ........................................................................................................ 3-1Move the Drive Motor .......................................................................................................... 3-2Reinstall the Front BDA ......................................................................................................... 3-3

Chapter 4 - Replace the Rear BDARemove the Rear BDA ......................................................................................................... 4-1Move the Drive Motor .......................................................................................................... 4-2Reinstall the Rear BDA ......................................................................................................... 4-4

Chapter 5 - Verify the Robotics Level and HeightVerify the Monorail is Level .................................................................................................. 5-1Verify the Picker Height ....................................................................................................... 5-3

Chapter 6 - Verify the Library OperationReattach the Library Panels and Components ................................................................ 6-1

Rear Access Panels ........................................................................................................ 6-1Front Panel Assembly ..................................................................................................... 6-1Media Drawers ................................................................................................................ 6-1

Power on the Library System ............................................................................................... 6-2Test the Library ...................................................................................................................... 6-2

Appendix A - Moving the LibraryMove the Library Out for Access ........................................................................................A-1Move the Library Back in Place ..........................................................................................A-2

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Part Number 104380-101 09/2005 vi

List of Figures

Chapter 1 - Introduction

Chapter 2 - Prepare the Library for Internal AccessFigure 2-1: Access Plates and Components That Need To Be Removed ...................... 2-1Figure 2-2: Left Bottom Rack Cover Trim Piece.................................................................. 2-2Figure 2-3: Front Panel Assembly Screw Locations............................................................ 2-3Figure 2-4: Location of the J3 GUI PWA Connector .......................................................... 2-3

Chapter 3 - Replace the Front BDAFigure 3-1: Locations of the J2 and J4 Drive PWA Connectors........................................ 3-1Figure 3-2: Location of the 1/8” Hex Shoulder Screw........................................................ 3-2Figure 3-3: Location of the Helical Coupling Front Cap Screw ....................................... 3-2Figure 3-4: Location of the Three Drive Motor Pan Head Screws .................................... 3-3

Chapter 4 - Replace the Rear BDAFigure 4-1: Base of Rear BDA and Connected Components .......................................... 4-1Figure 4-2: Location of the Rotary SPI PWA Connectors................................................... 4-2Figure 4-3: Location of the Helical Coupling Front Cap Screw ....................................... 4-3Figure 4-4: Location of the Three Drive Motor Pan Head Screws .................................... 4-3

Chapter 5 - Verify the Robotics Level and HeightFigure 5-1: Removing Shims from the BDA.......................................................................... 5-1Figure 5-2: Taking a Measurement with the Calipers ........................................................ 5-2Figure 5-3: Picker Height Tool in Position ............................................................................. 5-3Figure 5-4: Position the Picker Against the Picker Height Tool .......................................... 5-4

Chapter 6 - Verify the Library OperationFigure 6-1: Starting the Cartridge Cycle Test ..................................................................... 6-2

Appendix A - Moving the LibraryFigure A-1: Leveler Reference Marks on Floor....................................................................A-1Figure A-2: Positioning the Level ..........................................................................................A-2

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Part Number 104380-101 09/2005 1–1

1CHAPTER

Introduction

Each Z-Axis Belt Drive Assembly (BDA) consists of a pole with belts and pulleys that move one end of the Shuttle Assembly vertically inside the library.

IMPORTANT: Overland Storage recommends that the BDAs be replaced by an Overland Storage authorized service provider. Improper removal and replacement may result in damage to this part or library components which would void all existing warranties.

Replacement Process OverviewDescribed below are the major steps required to remove and replace the BDAs in a NEO 8000. Unless otherwise noted, all hardware is included in the BDA kit.

NOTE: Always retain any screws removed during this procedure. They will be reused to reinstall the appropriate components.

Step 1: Prepare the Library for Internal Access• Only if necessary, move the library system to provide working room.• Remove both side panels for easy access to change out the BDAs.• Optionally, remove access panels at the rear of the library.

Step 2: Replace the Front BDA• Remove the old BDA from the library.• Move the motor to the new BDA.• Install the new BDA into the library.

Step 3: Replace the Rear BDA• Disconnect the shuttle wiring from the rear BDA.• Remove the old BDA from the library.• Move the motor to the new BDA.• Install the new BDA into the library.

Step 4: Verify the Robotics Level and Height• Verify the shuttle robotics are level.• Verify that the picker is at the proper height.• Replace all components removed to allow access.

Step 5: Verify the Library Operation• Power on the library.• Check the library operation using the cartridge cycle test.

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1–2 Part Number 104380-101 09/2005

Chapter 1: Introduction

Required ToolsThese tools are required for the proper removal and replacement of the BDAs:

• #1 and #2 Phillips Screwdrivers• #2 Stubby Phillips Screwdriver• 1/8” Hex Key• 7/64” Hex Key• 3mm Hex Key• Calipers (digital calipers strongly recommended)• 607078-750, Tool Gage, Height, Z-Axis, LXN 8000• 607078-751, Tool Picker Height, Gage, LXN 8000

These tools are required only if you need to level the library:

• 6" or 10" Spirit Level (15cm or 25cm)• 10" Adjustable Wrench (260mm)

Electrostatic Discharge InformationA discharge of static electricity can damage static-sensitive devices. Proper packaging and grounding techniques are necessary precautions to prevent damage. To prevent electrostatic damage, observe the following precautions.

• Transport products in static-safe containers such as conductive tubes, bags, or boxes.• Keep electrostatic-sensitive parts in their containers until they arrive at static-free

stations.• Cover the library with approved static-dissipating material. • Use a wrist strap connected to the work surface and properly-grounded tools and

equipment.• Keep the work area free of non-conductive materials such as foam packing materials.• Make sure you are always properly grounded when touching a static-sensitive

component or assembly.• Avoid touching pins, leads, or circuitry.

Unpacking the Retrofit KitCarefully unpack the new components noting how they are packed in the shipping carton. When this procedure is complete, repack the old parts in the same container for shipment back to Overland Storage.

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Part Number 104380-101 09/2005 2–1

2CHAPTER

Prepare the Library for Internal Access

To simplify the replacement of the two internal BDAs, remove the Front Panel Assembly (FPA) and other components to provide easier access or visibility to the inside of the library (Figure 2-1).

Figure 2-1: Access Plates and Components That Need To Be Removed

NOTE: This procedure is based on the assumption that the library is located in a row of equipment racks that prevent access to the side panels. If the side panels can be removed, the process will be much easier. If moving the library is practical, refer to Appendix A, “Moving the Library.”

Removal of Media DrawersUsing Menu > Maintenance > Access All Drawers > Unlock All, release and remove all the media drawers to provide access to both the front and rear BDAs.

WARNING: Exercise care when removing the media drawers from the library units. Fully-loaded drawers weigh approximately 58 pounds (26.3 kg). Also, when the drawers are removed, the rails extend several inches beyond the back of the drawers. Use care when handling the drawers.

NOTE: Label the drawers so they can be returned to their correct positions when they are reinserted.

NEO

-800

1

NEO

-810

5

Removethe FPA

Remove ThisAccess Plate

Rear ViewFront View

Remove TheseMedia Drawers

Remove TheseMedia Drawers

Optionally,Remove TheseDrives/Plates

Remove ThisAccess Plate

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2–2 Part Number 104380-101 09/2005

Chapter 2: Prepare the Library for Internal Access

Power Down the Library

WARNING: Working with a powered NEO 8000 library may cause physical harm and severe damage to unit’s circuitry. Always power down a library before removing any panels.

1. Power down the library at the front panel.

2. Set the library circuit breakers to the OFF (“O”) position.

3. Remove and retain the power cords.

Remove Panels for AccessThe removal of various panels from the library is necessary to access the BDAs.

CAUTION: Follow ESD protocols when working with the PWA printed circuit boards.

Front Panel Assembly1. At the left bottom rack cover trim piece, remove and retain the screw attaching it to

the FPA (Figure 2-2).

Figure 2-2: Left Bottom Rack Cover Trim Piece

2. Push the trim piece back and up to remove it.

3. Repeat Steps 1–2 for the right bottom rack cover trim piece.

4. At the base of the FPA, remove the pan head screws on each side (Figure 2-3).

NEO

-805

0

RemoveThis Pan

Bottom RackCover Trim

FPA

Head Screw

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Part Number 104380-101 09/2005 2–3

Remove Panels for Access

Figure 2-3: Front Panel Assembly Screw Locations

5. Supporting the FPA, remove the flat head screws at the top on each side.

NOTE: Be sure to keep the two sets of screws separate. The FLAT head screws must be used at the TOP of the FPA to prevent interference with the operation of the top drawers.

6. Pivot the FPA out far enough to remove the J3 connector (Figure 2-4) at the top of the GUI PWA.

Figure 2-4: Location of the J3 GUI PWA Connector

7. Remove the cable from the retainers on the back side of FPA and set aside the FPA.

CAUTION: Lay the FPA on a safe, secure surface that won’t damage the bezel.

NEO

-800

1

RemoveFlat Head

Screws

RemovePan HeadScrews

J3

J6

J5

J2

CON2

Unplug

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2–4 Part Number 104380-101 09/2005

Chapter 2: Prepare the Library for Internal Access

Rear Access PanelsAt the rear of the library, remove and retain the top-right and the bottom-right access panels and hardware.

For additional visibility and access, remove the drives or drive panels 1, 2, 3, 4, 11, and 12 and their associated drive dividers (Figure 2-1).

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Part Number 104380-101 09/2005 3–1

3CHAPTER

Replace the Front BDA

You are now ready to replace the old BDAs. Each new BDA comes ready to install. The only requirement is moving the drive motor from the old assembly to the new one.

CAUTION: Follow ESD protocols when working with the Drive PWA printed circuit boards.

Remove the Front BDA1. Remove and retain the two screws attaching the front Drive PWA cover.

2. Unplug the J2 and J4 connectors from the Drive PWA (Figure 3-1).

Figure 3-1: Locations of the J2 and J4 Drive PWA Connectors

NOTE: You can temporarily reattach the cover to protect the Drive PWA during extraction.

J2 J6J5J4 J3

Unplug

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3–2 Part Number 104380-101 09/2005

Chapter 3: Replace the Front BDA

3. Using the 1/8” hex key, remove and retain the shoulder screw and washers (Figure 3-2) that attach the monorail bracket to the BDA.

Figure 3-2: Location of the 1/8” Hex Shoulder Screw

4. Remove and retain the bottom screws holding the BDA to the mounting bracket.

5. Supporting the BDA, remove and retain the top screws from the mounting bracket.

6. Moving the top of the BDA to the left and the bottom slightly to the right (to clear the mounting brackets), remove the assembly from the library.

Move the Drive Motor1. With the BDA positioned securely, use a 7/64” hex key to loosen the front cap screw

on the drive’s helical coupling (Figure 3-3).

Figure 3-3: Location of the Helical Coupling Front Cap Screw

NEO

-804

2a

Shoulder

MonorailBracket

Z-Axis BDA

Screw

BDA MountingBottomMountingBracket

Screws

Hex

Front HelicalCoupling CapScrew

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Part Number 104380-101 09/2005 3–3

Reinstall the Front BDA

2. Using a 3mm hex key, remove and retain the three cap screws holding the motor to the BDA (Figure 3-4).

Figure 3-4: Location of the Three Drive Motor Pan Head Screws

3. Slide the motor off the old BDA’s drive shaft

4. Slide the motor onto the new BDA’s drive shaft.

5. Using a 3mm hex key, attach the motor to the new BDA using three retained cap screws.

6. Using a 7/64” hex key, tighten the front cap screw on the drive’s helical coupling.

Reinstall the Front BDANOTE: You can temporarily reattach the cover to protect the Drive PWA during insertion.

1. Holding the top of the BDA to the left and the bottom slightly to the right, insert the assembly into the library.

2. Supporting the BDA, use the two retained screws to reattach it to the top mounting bracket.

3. Use the two retained screws to reattach the BDA to the bottom mounting bracket.

4. Using the 1/8” hex key, use the retained shoulder screw and washers (Figure 3-2) to reattach the monorail bracket to the BDA.

NOTE: Be sure there are two washers used with the monorail bracket shoulder screw. Add a second washer if necessary.

5. On the Drive PWA, reattach the J2 and J4 connectors.

6. Use the two retained screws to reattach the Drive PWA cover.

NEO

-804

2b

Remove TheseThree Screws

Drive Motor

Motor PWA

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3–4 Part Number 104380-101 09/2005

Chapter 3: Replace the Front BDA

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Part Number 104380-101 09/2005 4–1

4CHAPTER

Replace the Rear BDA

CAUTION: Follow ESD protocols when working with the PWA printed circuit boards.

Remove the Rear BDAThe Rotary SPI PWA and Shuttle Support need to also be removed from the rear BDA before it can be replaced (Figure 4-1).

Figure 4-1: Base of Rear BDA and Connected Components

1. At the rear drive motor, remove and retain the two screws attaching the rear Drive PWA cover.

2. Unplug the J2 and J4 connectors from the Drive PWA.

NOTE: You can temporarily reattach the cover to protect the Drive PWA during extraction.

NEO

-804

2b

Z-Axis BDA

Cable Clip

Drive Motor

Belt

Rotary Motor

ShuttleSupport Bracket

and Optical Sensor Cables

RotarySPI PWA

BottomMounting

Bracket

Cable Ties

MountingBracket

D-Clamp

BracketScrews

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4–2 Part Number 104380-101 09/2005

Chapter 4: Replace the Rear BDA

3. On the Rotary SPI PWA, unplug the J3, J4, J6, and J7 connectors (Figure 4-2).

Figure 4-2: Location of the Rotary SPI PWA Connectors

4. Remove and retain the cable clip and cut the two cable ties holding the Shuttle Signal cable to the Rotary SPI PWA mounting bracket.

5. From the front, remove and retain the two screws holding the Shuttle support bracket to the Belt mounting bracket.Lay the bracket and cables down on the bottom of the library.

6. From the rear, remove and retain the two screws holding the Rotary SPI PWA mounting bracket to the Belt mounting bracket.Lay the bracket and cables down on the bottom of the library.

7. Carefully remove the Rotary Motor and Optical Sensor cables from under the Belt mounting bracket and move them to the front removing them from the D-clamp.

8. Using the 1/8” hex key, remove and retain the shoulder screw and washers (Figure 4-1) that attach the monorail bracket to the BDA.

9. Remove and retain the bottom screws holding the BDA to the mounting bracket.

10. Supporting the BDA, remove and retain the top screws from the mounting bracket.

11. Tilting the BDA to clear all the internal components, remove the assembly from the library.

Move the Drive Motor1. With the BDA positioned securely, use a 7/64” hex key to loosen the front cap screw

on the drive’s helical coupling (Figure 4-3).

J2

J6

J1

J4 J3

J7

Unplug

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Part Number 104380-101 09/2005 4–3

Move the Drive Motor

Figure 4-3: Location of the Helical Coupling Front Cap Screw

2. Using a 3mm hex key, remove and retain the three cap screws holding the motor to the BDA (Figure 4-4).

Figure 4-4: Location of the Three Drive Motor Pan Head Screws

3. Slide the motor off the old BDA’s drive shaft

4. Slide the motor onto the new BDA’s drive shaft.

5. Using a 3mm hex key, attach the motor to the new BDA using three retained cap screws.

6. Using a 7/64” hex key, tighten the front cap screw on the drive’s helical coupling.

Front HelicalCoupling CapScrew

NEO

-804

2b

Remove TheseThree Screws

Drive Motor

Motor PWA

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4–4 Part Number 104380-101 09/2005

Chapter 4: Replace the Rear BDA

Reinstall the Rear BDANOTE: You can temporarily reattach the cover to protect the Drive PWA during insertion.

1. Tilting the BDA to clear all the internal components, insert the assembly into the library.

2. Supporting the BDA, use the two retained screws to reattach it to the top mounting bracket.

3. Use the two retained screws to reattach the BDA to the bottom mounting bracket.

4. Using the 1/8” hex key, use the retained shoulder screw and washers (Figure 4-1) to reattach the monorail bracket to the BDA.

NOTE: Be sure there are two washers used with the monorail bracket shoulder screw. Add a second washer if necessary.

5. Carefully route the Rotary Motor and Optical Sensor cables under the Belt mounting bracket and to the rear, reattaching them in the D-clamp.

6. From the rear, use the two retained screws to reattach the Rotary SPI PWA mounting bracket to the Belt mounting bracket.

7. From the front, use the two retained screws to reattach the Shuttle support bracket to the Belt mounting bracket.

8. Reposition the Shuttle Signal cable on the Rotary SPI PWA mounting bracket and reattach it using the cable clip.

9. Loop a new cable tie around the Shuttle Signal cable on the Rotary SPI PWA mounting bracket to secure the cable.

10. Loop a new cable tie around the Shuttle Signal cable and the pulley cable where it attaches to the Belt mounting bracket to secure it.

11. On the Rotary SPI PWA, reattach the J3, J4, J6, and J7 connectors.

12. On the Drive PWA, reattach the J2 and J4 connectors.

13. Use the two retained screws to reattach the Drive PWA cover.

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Part Number 104380-101 09/2005 5–1

5CHAPTER

Verify the Robotics Level and Height

Once you have completed the change-out of the belt drive assemblies, you must verify that the shuttle assembly robotics monorail is level and the picker is at the correct height. Shims, clear plastic washers with a cut on one side, are used to adjust the height.

CAUTION: If the library was moved out to facilitate the BDA replacement, verify that it is level before continuing (see Appendix A).

NOTE: The NEO 8000 is designed so that the rear BDA is slightly higher than the front. Shims are only used on the front BDA.

Verify the Monorail is LevelThe Shuttle Monorail must be level for the picker to function correctly. Shims are used at the base of the front BDA to adjust the monorail level. These come in two thicknesses:

• 0.020” thick (P/N 969401-101)• 0.030” thick (P/N 969401-102)

Follow these steps to verify that the monorail for the shuttle assembly is level.

1. Remove any shims from the front BDA before continuing.To remove them, manually lift the Belt Mounting Bracket a couple of inches and pull the shims out (Figure 5-1).

Figure 5-1: Removing Shims from the BDA

2. Verify that the monorail is seated at the bottom of the chassis.

3. Position the Height Gage Tool (P/N 607078-750) on the two lower drawer slide rails with the groove centered over the end of the fixed portion of the monorail (Figure 5-2).

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5–2 Part Number 104380-101 09/2005

Chapter 5: Verify the Robotics Level and Height

NOTE: Be sure the tool is over the fixed portion and not the rotating portion of the monorail. It should be positioned over the monorail’s flat area, not the grooves or teeth.

Figure 5-2: Taking a Measurement with the Calipers

4. Position the digital calipers vertically on the tool at the groove.

CAUTION: Visually verify that the calipers are vertical to ensure an accurate reading.

5. Extend the calipers down to the monorail and note the reading.

NOTE: The actual reading is irrelevant. You are only establishing a point of reference with the calipers. All that is important is that the distance established by the calipers is maintained for the next reading. Do not allow the calipers to change.

6. Without changing the existing reading, zero out the calipers.

7. Move the Height Gage Tool to the front of the monorail so that it still straddles the two lower drawer slide rails and the groove is still centered over the monorail.

8. Without changing the existing reading, repeat Steps 4–5 for the front of the monorail.The new measurement should only show the difference between the front and back heights of the monorail. This indicates the shims required, if any, to level the monorail to no more than ±0.010” difference.

CAUTION: If the measurement is negative, repeat Steps 2–8 making sure the calipers are vertical for both measurements. If the measurement is still negative, then the rear of the monorail is lower than the front. Contact Overland Technical Support.

9. Repeat Steps 2–8 to confirm the height difference.

NOTE: It may be necessary to do this a few times and take an average.

Calipers

Caliper Contact Height Gage Tool

Tool

at Monorail End (607078-750)

DrawerSlideRail

Groove

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Part Number 104380-101 09/2005 5–3

Verify the Picker Height

10. Use the table (Table 5-1) to determine the combination of shims to add to the front BDA.

NOTE: Because the rear measurement is located one-third the distance from the rear of the monorail, the front measurement must be adjusted by adding 15% to accurately reflect the difference between the front and the rear. The table allows for this correction.

Verify the Picker HeightOnce the monorail is within tolerances, verify the shuttle picker tool is at the proper height.

1. Attach the Picker Height Tool over the lower bulkhead fiducial block (Figure 5-3).

Figure 5-3: Picker Height Tool in Position

Table 5-1: Recommended Shim Usage for Monorail Leveling

Caliper Reading 0.020” Shims 0.030” Shims

0.000” to 0.009” -- --

0.010” to 0.024” 1 --

0.025” to 0.034” -- 1

0.035” to 0.044” 2 --

0.045” to 0.054” 1 1

0.055” to 0.064” -- 2

0.065” to 0.074” 2 1

0.075” to 0.084” 1 2

0.085” to 0.094” 2 2

FiducialBlock

PickerHeight

Tool(607078-751)

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5–4 Part Number 104380-101 09/2005

Chapter 5: Verify the Robotics Level and Height

2. Rotate the shuttle by hand and position it so that the picker extends enough to just touch the Picker Height Tool (Figure 5-4).

Figure 5-4: Position the Picker Against the Picker Height Tool

3. Verify that the picker aligns with the top line on the Picker Height Tool.

4. If necessary, add shims to raise the monorail.

a. Use the lines on the Picker Height Tool to calculate the number and type of shims to add based on the lines being 0.030” apart.

CAUTION: If the picker is above or far below the bottom line on the Picker Height Tool, contact Overland Technical Support.

b. Add the calculated number and type of shims to the rear BDA (Figure 5-1).

c. Add the same number and type of shims to the front BDA.

d. Recheck the picker alignment to verify success.

Table 5-2: Recommended Shim Usage for Monorail Height

Picker Position 0.020” Shims 0.030” Shims

At or slightly below the top line -- --

Halfway between top and middle lines 1 --

At or slightly below the middle line -- 1

Halfway between middle and bottom lines 1 1

At or slightly below the bottom line -- 2

PickerHeightTool

Picker

AlignmentGrooves

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Part Number 104380-101 09/2005 6–1

6CHAPTER

Verify the Library Operation

Once the new BDAs are in place, you need to check that everything functions correctly.

CAUTION: Follow ESD protocols when working with the PWA printed circuit boards.

Reattach the Library Panels and ComponentsYou need to replace all the components removed to provide easier access.

Rear Access Panels At the rear of the library, use the retained hardware to reattach the top-right and the bottom-right access panels.

If necessary, use the retained hardware to reinstall the drives or drive panels 1, 2, 3, 4, 11, and 12 and their associated drive dividers.

Front Panel Assembly1. Supporting the FPA next to its normal position, reattach the J3 connector at the

top of the GUI PWA.

2. Insert the J3 cable back into the retainers on the back side of FPA.

3. Supporting the FPA in its normal position, use the retained flat head screws at the top on each side to reattach the FPA.

NOTE: Only use the flat head screws when fastening the top of the FPA to the library to prevent interference with the operation of the drawers.

4. At the base of the FPA, use the retained pan head screws on each side to secure the FPA.

5. At the bottom, push the left cover trim piece down and forward to insert it.

6. Use the retained screw to reattach the trim piece to the FPA.

7. Repeat Steps 5–6 for the right bottom rack cover trim piece.

Media DrawersUsing the labels on the media drawers, reinsert them into their proper positions in the library. Push them back until they latch.

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6–2 Part Number 104380-101 09/2005

Chapter 6: Verify the Library Operation

Power on the Library System1. Reattach all the power cords.

2. Set the library circuit breakers to the ON (“|”) position.

Test the LibraryUse the Cartridge Cycle Diagnostic from the GUI touch screen to validate the functionality of the new assemblies.

NOTE: This test randomly moves and redistributes the tape cartridges in the library requiring that it be re-inventoried before putting it back in service. In lieu of this automated test, you can manually move selected tapes to validate the functionality of the library.

1. Verify that 5 or more cartridges are available from an enabled drawer or Mail Slot.

2. Select Menu > Diagnostics > Cartridge Cycle > Start (see Figure 6-1).

Figure 6-1: Starting the Cartridge Cycle Test

3. Allow the test to run for 30 minutes or 20-25 cartridge move iterations.

If the test fails, contact Overland Storage Technical Support. Refer to “Overland Storage Technical Support” in the Preface for contact information.

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Part Number 104380-101 09/2005 A–1

AAPPENDIX

Moving the Library

If the library must be moved to perform the Z-Axis BDA retrofit, use the following procedures to move it out, move it back, and then level it.

Move the Library Out for AccessTo reduce the weight and make it easier to move the library, the drawers and mail slot can be removed before moving the library.

1. With the power on, release and remove all the media drawers from the library by pressing Menu > Maintenance > Access All Drawers > Unlock All.Release the manual catches and carefully remove each drawer.

WARNING: Use care when removing the media drawers. Fully-loaded drawers weigh approximately 58 pounds (26.4 kg). Exercise care when removing the drawers from the library.

2. Release and remove the Mail Slot by pressing Mail Slot Access.

3. Power down the library.

a. Power off the library.

b. Set the library circuit breakers to the OFF (“O”) position.

c. Remove and retain the power cords.

4. Verify that the library leveler reference marks are still visible on the floor (see Figure A-1). If necessary, remark the location and position of the levelers so it can be returned to the same position.

Figure A-1: Leveler Reference Marks on Floor

5. Using a wrench, turn each leveler 3-4 turns counterclockwise to raise it off the floor.

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A–2 Part Number 104380-101 09/2005

Appendix A: Moving the Library

6. Using at least 2 people, roll the library system to an open location.

Continue with the standard removal and replacement of the Z-Axis BDAs.

Move the Library Back in PlaceOnce the new BDAs are in place, you can move the library back to its original position.

1. Using at least 2 people, roll the library back in place, aligning the levelers with the appropriate reference marks on the floor.

2. Using a wrench, turn each leveler 3-4 turns clockwise until it makes firm contact with the floor and lines up with the reference marks.

NOTE: Be sure the library has been raised high enough so none of the casters touch the floor.

3. Place a level, front to rear, on the top side edge of the library (Figure A-2).

Figure A-2: Positioning the Level

4. Note the position of the bubble. Raise both of the front legs or both of the rear legs the same amount to achieve a level front-to-rear reading.

5. Place the level across the top front edge of the library.

6. Note the position of the bubble. Raise both of the left feet or both of the right feet the same amount to achieve a level side-to-side reading.

7. Recheck the level from front-to-rear and from side-to-side. Adjust as needed until the library is level.

NEO

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