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

FIN #: I0666-1

Create Date: May/25/01

Keywords: 

Replacement of defective power supplies in E220R/E420R systems

Top FIN/FCO Report: No

Products Reference: Hot Swappable Power Supply

Product Category: Server / Service

Product Affected: 

Mkt_ID   Platform   Model   Description            Serial Number
------   --------   -----   -----------            -------------
Systems Affected
----------------
   -       E220R      ALL    Ultra Enterprise 220R        -
   -       E420R      ALL    Ultra Enterprise 420R        -
 
X-Options Affected
------------------
   -         -         -          -                       -

Parts Affected: 

Part Number   	Description  			 Model
-----------   	-----------  			 -----
300-1449-02     PS,380 WATT,5OUTPUT,HOT PLUG	   -
300-1449-03	PS,380 WATT,5OUTPUT,HOT PLUG	   -

References: 

BugId:  4307681 - E420R/E220R Redundant PSUs lock into a fail state 
                  after A/C i/p interruption. 
        4449598 - Power Supply Unit becomes no output on E420R.

ECO:	WO_18802 
        WO_20661

ESC:    524659 
        530248
 
MANUAL: 806-1080-10: Sun Enterprise 420R Server Service Manual
 	806-1081-10: Sun Enterprise 220R Server Service Manual

Issue Description: 

Improper service procedures with the E220R/E420R power supplies could
result in system downtime.  In addition, under certain circumstances,
the hot swapping functionality for the redundant power supplies may
fail.

Multiple power supply failure issues in E220R or E420R systems have
been reported from the field.  Based on an evaluation of reported
failure modes and testing of quarantined power supplies returned from
the field, two issues have become apparent.  
  
 --------  
|ISSUE 1:|
 --------  

False error conditions or system crash/downtime could result from rapid
seating and unseating of power supplies as well as rapid unseating and
reseating of the power cord or brief interruptions in power.  Power
supplies will also shut down automatically in response to certain
over-temperature and power fault conditions.
 
This issue pertains to BOTH the 300-1449-02 (with or without ECO label 
attached) and the 300-1449-03 power supplies.

 --------  
|ISSUE 2:|
 --------  
  
Failure of the operational power supply is caused by an overly
sensitive fan fail circuit detecting a 12v droop. No matter how long
you wait, once you insert the second supply, load sharing begins and a
failure of the operational supply is possible.  This failure has been
seen in a very small percentage of power supplies.

Power supply part number 300-1449-02 is affected by Issue 2.
Approximately 280,000 of these power supplies have been shipped in
E220R/E420R systems as FRUs.  
 
A permanent fix for issue 2 has been incorporated into stocked
inventory of the 300-1449-02 and is identifiable by a label with
WO_20661 on it.  In addition, the 300-1449-03 has a redesigned daughter
board in it which has eliminated the sensitive fan circuit.
 
Please follow the procedures in the Corrective Action section when
replacing a power supply in any E220R/E420R system.

Implementation: 

---
         |   |   MANDATORY (Fully Pro-Active)
          ---    
          
   
          ---
         |   |   CONTROLLED PRO-ACTIVE (per Sun Geo Plan) 
          --- 
          
                                 
          ---
         | X |   REACTIVE (As Required)
          ---

Corrective Action: 

The following recommendation is provided as a guideline for authorized
Enterprise Services Field Representatives and Warranty Customers who
may be encountering the above mentioned problem.

NOTE: These procedures should only be followed when a power supply
      failure has been experienced and requires replacement.  This
      FIN does not recommend or authorize proactive replacement of
      power supplies.

 --------  
|ISSUE 1:|
 --------  
   
When removing a hot-swappable power supply, do not dis-engage and
re-engage the power supply in rapid succession.  Always remove a power
supply completely before re-inserting the same power supply or a
replacement power supply.  	 

Wait at least 10 seconds after power-on of a redundant power supply
before removing power from the primary power supply or before removing
the primary power supply.  It takes a minimum of three seconds for the
redundant power supply to come up to regulation. 
  
See Chapter 5 in the Sun Enterprise 420R Server Service Manual or the
Sun Enterprise 220R Server Service Manual for details about removing
and replacing power supplies.
 
 --------  
|ISSUE 2:|
 --------  
   
When replacing a defective E220R/E420 power supply, replace the
defective power supply with a modified -02 (labeled with ECO
WO_20661) or a -03 power supply.  Be aware that in a small percentage
of cases, hot swapping will not work and the original operating power
supply, if version -02, may shut down.  This could cause the system to
lose all power and the operating systems and any applications will halt.  

To prevent this potential occurrence from causing unplanned system
downtime and/or filesystem damage for mission critical systems, it is
advisable to bring down the OS in an orderly manner before replacing
the defective power supply.

If the original power supply does shut down, unplug the AC power cord, 
wait at least 10 seconds, and then plug the cord in.

Comments: 

None 
     
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Implementation Footnote: 

i)   In case of MANDATORY FINs, Enterprise Services will attempt to    
     contact all affected customers to recommend implementation of 
     the FIN. 
   
ii)  For CONTROLLED PROACTIVE FINs, Enterprise Services mission critical    
     support teams will recommend implementation of the FIN  (to their  
     respective accounts), at the convenience of the customer. 

iii) For REACTIVE FINs, Enterprise Services will implement the FIN as the   
     need arises.
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