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

FCO #: A0173-1

Status: inactive

Date: Jun/19/2001

Keywords: 

Ultra 5 and Ultra 10 systems with Sapphire Red Modules have shown an increase in early life failures

SunAlert: N

Top FIN/FCO Report: Yes

Products Reference: Sapphire Red CPU Modules 360/400/440MHz

Product Category: DeskTop / System CPU Module

Product Affected: 

Mkt_ID   Platform   Model   Description               Serial Number
------   --------   -----   -----------               -------------
Systems Affected:
------- --------
  -      A22          -     360/400/440MHz Ultra 10   xx030xxxxx - xx048xxxxx
  
  -      A21          -     360/400/440MHz Ultra 5    xx030xxxxx - xx048xxxxx
  
  -    SPARCEngine UltraAXi    Motherboard CPU        xx030xxxxx - xx048xxxxx

X-Options Affected
--------- -------
X2754A  E10000    -   E10000 System Service Processor   xx030xxxxx - xx048xxxxx

Parts Affected: 

Part Number   Description                  Model
-----------   -----------                  -----
501-5741-01   CPU Module SR 400MHz 2MB       -
501-5148-06   CPU Module SR 360MHz .25MB     -
501-5149-08   CPU Module SR 440MHz 2MB       -

(SCSI Devices)
Type    Vendor    Model     SerialNumber(Min)    SerialNumber(Max)    Firmware
----    ------    -------   ------------------   ------------------   --------
N/A

References: 

WWStopShip: WSS001#03700 
  DPCO: 226:  Rework all AT&S FABs (Apr/12/01)
  DPCO: 215:  Purge and Hold all AT&S FABs (Feb/09/01)
  DPCO: 271.A EMEA & APAC Returns

Issue Description: 

There has been a recent increase in early life failure rates on Ultra 10 and
Ultra 5 systems containing 360MHz, 400MHz, and 440MHz (Sapphire Red) CPU
Modules shipped between week 30 through week 48.  Only CPU modules
manufactured with one specific FAB are affected.  The affected system serial
number range is xx030xxxxx to xx048xxxxx.

The Primary symptoms associated with the affected modules are as follows;

- system hang/lockup
- drops to ok prompt
- spontaneous reboots

In some instances, you may also see CPU Panic, panic errors or system panic
bad trap.

The root cause of this early life failure is related to a vendor manufacturing
process which resulted in dry film mask contamination on the pads.  Out of
approximately 135,000 Sapphire Red modules shipped between week 30 and 48 of
year 2000, it is estimated that about 45,000 are from the AFFECTED FAB in
question.  No other FABs are affected by this issue.

Corrective action was implemented within Sun Manufacturing via Worldwide
StopShip/Purge WSS001#03700 on December 31, 2000.  Corrective action was
implemented within Enterprise Services via DPCO# 215 as of February 9, 2001.
A rework process was implemented via DPCO# 226 as of April 12, 2001.

Good modules can be identified as NONAFFECTED FAB by having "DPCO 215"label
on the FRU packaging.  Reworked modules from the affected FAB will have a
"DPCO 226A" or "DPCO 226B" label.  Reference the Corrective Action section
for more information.

If needed an end-user Customer Letter has been developed and can be accessed via
the below URLs in either postscript or StarOffice versions;

  http://sdpsweb.EBay/FIN_FCO/FCO/FCO_A0173-1_Dir/Customer_Letter.ps

  http://sdpsweb.EBay/FIN_FCO/FCO/FCO_A0173-1_Dir/Customer_Letter.sdw

Implementation: 

---
|   |   MANDATORY (Fully Pro-Active)
 ---

 ---
|   |   CONTROLLED PRO-ACTIVE (per Sun Geo Plan)
 ---

 ---
| X |   UPON FAILURE (As Required)
 ---

Replacement Time Estimate: 

0.5 hours

Special Considerations: 

Because the final Root Cause has determined this to be an Early Life issue,
systems running more than 72 hours are at little, if any, risk of experiencing
this problem.  Therefore, Sun recommends NOT replacing modules in these
mature systems if no failure has been experienced, as this will only cause
unnecessary customer down time and may induce a problem in an otherwise
running system.

Corrective Action: 

Upon failure replace AT&S FABs as follows;

 501-5149-08 (or below) with 501-5149-08 (or above) having a "DPCO 226A"
             or "DPCO 226B" label, or having a "WSS001#03700" label, or
             with a NONAFFECTED FAB.

 501-5148-06 (or below) with 501-5148-06 (or above) having a "DPCO 226A"
             or "DPCO 226B" label, or having a "WSS001#03700" label, or
             with a NONAFFECTED FAB.

 501-5741-01 with 501-5741-01 (or above) (or above) having a "DPCO 226A"
             or "DPCO 226B" label, or having a "WSS001#03700" label, or
             with a NONAFFECTED FAB.

*** CAUTION! TO AVOID ANY MODULE DAMAGE refer to the following CPU module
    handling document;

     http://sdpsweb.EBay/FIN_FCO/FCO/FCO_A0173-1_Dir/IIi.Module.Handling

For detailed system inspection and replacement procedures refer to the
"Sun Ultra 5 and Ultra 10 CPU Module Inspection and Replacement Guide";

  http://acts.ebay/ready/u5_u10/U5-U10-rework.pdf

To identify a suspect module:

 1. Check the system to see if it falls in the serial number range.
 2. Check the module to see if it is an AT&S fab per the inspection
    guidelines set forth below.

For detailed instructions please see below pdf file:

  http://sdpsweb.ebay/FIN_FCO/FCO/FCO_A0173-1_Dir/ModuleInspection.pdf

Comments: 

For information on previous field communications on this subject reference
the following URLs;

 http://onestop/hw/u5.shtml

 http://onestop/hw/u10.shtml

Billing Type: 

Warranty: Sun will provide parts at no charge under Warranty
           Service. On-Site Labor Rates are based on how the
           system was initially installed.

 Contract: Sun will provide parts at no charge. On-Site Labor Rates
           are based on the type of service contract.

 Non Contract: Sun will provide parts at no charge. Installation by
               Sun is available based on the On-Site Labor Rates
               defined in the Price List.

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Implementation Footnote: 

________________________

i)   In case of Mandatory FCOs, Enterprise Services will attempt to contact
     all known customers to recommend the part upgrade.

ii)  For controlled proactive swap FCOs, Enterprise Services mission critical
     support teams will initiate proactive swap efforts for their respective
     accounts, as required.

iii) For Replace upon Failure FCOs, Enterprise Services partners will implement
     the necessary corrective actions as and when they are required.

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All released FINs and FCOs can be accessed using your favorite network
browser as follows:

SunWeb Access:
______________

* Access the top level URL of http://sdpsweb.EBay/FIN_FCO/

* From there, select the appropriate link to query or browse the FIN and
  FCO Homepage collections.

SunSolve Online Access:
_______________________

* Access the SunSolve Online URL at http://sunsolve.Central/

* From there, select the appropriate link to browse the FIN or FCO index.

Supporting Documents:
____________________

Supporting documents for FIN/FCOs can be found on Edist.  Edist can be
accessed internally at the following URL: http://edist.Central/.

* From there, follow the hyperlink path of "SunService Documentation" and
  click on "FIN & FCO attachments", then choose the appropriate folder,
  FIN or FCO.  This will display supporting directories/files for FINs or
  FCOs.

Internet Access:
_______________

* Access the top level URL of https://infoserver.Sun.COM

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General:
________

Send questions or comments to finfco-manager@sdpsweb.EBay

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