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

FIN #: I0677-1

Create Date: Jun/01/01

Keywords: 

StorEdge T3 Array battery refresh cycle should be changed to 28 days to avoid premature battery failure

SunAlert: No

Top FIN/FCO Report: Yes

Products Reference: T3 Array Battery Refresh Cycle

Product Category: Storage / Service

Product Affected: 

Mkt_ID   Platform   Model   Description               Serial Number
------   --------   -----   -----------               -------------
Systems Affected
----------------
  -      Anysys     All     System Platform Independent     -

X-Options Affected
------------------
  -      T3         ALL     T3 StorEdge Array               -
  -      T300       ALL     T300 StorEdge Array             -
  -      T301       ALL     T301 StorEdge Array             -

Parts Affected: 

Part Number   Description   Model
-----------   -----------   -----
     -             -          -

References: 

BugId:   4403799 - 325 Watt Power Supply w NiMH Battery on T3 failed.
         4429265 - Battery scheduler file needs to revert to 28 days.

PatchId: 109115-09 or higher: T3 1.17: System Firmware Update.

ESC:     529253

Manual:  806-4213-11 - Sun StorEdge T3 Disk Tray Field Service Manual.

Infodoc: 24714 - T3 Battery Management and the Battery Scheduler Daemon.

Issue Description: 

Design limitations and 14 day battery refresh cycles within the
charging circuit of the StorEdge T3 Array are contributing to
early-life failures of the T3 Power Cooling Unit Battery Pack.  These
failures account for 20% of the Power Cooling Unit failures in the
field.  Resetting the refresh cycle from 14 days to 28 days will extend
the life of the Power Cooling Unit battery packs, thus reducing the
number of battery failures and addressing customer concerns about
battery quality.
 
The T3 contains dual power supplies and when one fails the other power
supply takes over and the failure is reported in the syslog file.  At
this point the data cache is no longer used.  This is a safeguard
against losing data in the cache during a subsequent powerfail.

Following is an example of battery failure messages:

  Jan 11 15:38:10 law10-u1-r8.law10.cust.com BATD[1]: N: Battery Refreshing
         cycle starts from this point.
  Jan 11 15:38:11 law10-u1-r8.law10.cust.com LPCT[1]: N: u1pcu1: Refreshing
         battery
  Jan 11 15:38:14 law10-u1-r8.law10.cust.com LPCT[1]: N: u2pcu1: Refreshing
         battery
  Jan 11 15:38:17 law10-u1-r8.law10.cust.com LPCT[1]: N: u1pcu1: Battery
         not OK

** Expected message...system has detected drop in voltage from u1pcu1 as a
   result of the discharge test.

  Jan 11 15:38:22 law10-u1-r8.law10.cust.com BATD[1]: N: u1pcu1: hold time
         was 12 seconds.
  Jan 11 15:38:25 law10-u1-r8.law10.cust.com BATD[1]: W: u1pcu1: Replace
         battery, hold time low.
  Jan 11 15:52:48 law10-u1-r8.law10.cust.com LPCT[1]: N: u2pcu1: Battery
         not OK

** u2pcu1 expected message....

  Jan 11 15:52:50 law10-u1-r8.law10.cust.com BATD[1]: N: u2pcu1: hold time
         was 878 seconds.

** u2pcu1 passed the test as this is about a 14 minute hold time.

  Jan 12 06:38:21 law10-u1-r8.law10.cust.com BATD[1]: W: u1pcu1: Replace
         battery, hold time low.
  Jan 12 06:38:21 law10-u1-r8.law10.cust.com BATD[1]: N: u1pcu1 Battery
         took too long to recharge.
  Jan 12 06:38:21 law10-u1-r8.law10.cust.com BATD[1]: N: u1pcu2:skips
         battery refresh because the other PCU u1pcu1 : PCU1 hold time low

** Expected we would skip the u1pcu2 refresh test since u1pcu1 has failed.

  Jan 12 06:38:23 law10-u1-r8.law10.cust.com LPCT[1]: N: u2pcu2: Refreshing
         battery
  Jan 12 06:52:09 law10-u1-r8.law10.cust.com LPCT[1]: N: u2pcu2: Battery
         not OK
  Jan 12 06:52:12 law10-u1-r8.law10.cust.com last message repeated 1 time
  Jan 12 06:52:15 law10-u1-r8.law10.cust.com BATD[1]: N: u2pcu2: hold time
         was 833 seconds.

** u2pcu2 is ok based on this hold time.

  Jan 12 07:02:47 law10-u1-r8.law10.cust.com pshc[1]: N: fru stat
  Jan 12 07:03:27 law10-u1-r8.law10.cust.com pshc[1]: N: refresh -s
  Jan 12 18:01:24 law10-u1-r8.law10.cust.com BATD[1]: N: Battery Refreshing
         cycle ends at this point.

Approximately 20% of the Power Cooling Unit failures are due to reduced
battery life as a result of heat generated during battery refresh
cycles.  Under specified conditions, the batteries can face a
temperature much higher than allowed by the supplier.  This higher
temperature rendors the charging circuit inadaquate, further reducing
the battery life.
 
This problem can be solved by setting a longer interval between battery
refresh cycles.  The refresh cycle has previously been set by Sun
Manufacturing to 14 days.  Manufacturing will increase the refresh
cycle time to 28 days on new T3 units.  T3 units already in the field
should be modified according to the recommended actions below.

Implementation: 

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

Corrective Action: 

An Authorized Enterprise Field Service Representative may avoid the
above mentioned problems by following the recommendations as shown
below.

The problem is fixed by upgrading to 1.17a or newer firmware via Patch
109115-09 or newer.  

. The "Refresh Schedule Adjustment Procedure" is available as a temporary
  workaround until the firmware is installed.

. The "Refresh Schedule Adjustment Procedure" is available (below) as a 
  temporary workaround if the firmware is not installed.
        
  . These are the steps to change the StorEdge T3 Array Power Cooling Unit
    battery refresh cycle from 14 days to 28 days.

  . Reference: Sun StorEdge T3 Disk Tray Field Service Manual, 
               Chapter 7, paragraphs 7.4.1 and 7.4.2.

  Refresh Schedule Adjustment Procedure
  -------------------------------------

  1. Telnet to the T3 and login as "root".

  2. Check to see if the T3 is running a battery refresh by typing 
     "refresh -s " from the T3 CLI.

        If yes, decide whether or not to kill the task. 
	
	  A. To kill the task type "refresh -k " and proceed to 
             step 2.
	
		  -- or -- 
		
	  B. To allow the task to continue, wait until the refresh task is 	
             complete.  Check status by typing "refresh -s ".  When
	     the refresh is complete proceed to step 2.

  3. Ftp from a workstation to the T3 to have refresh scheduler adjusted.

  4. Get /etc/schd.conf.

  5. Edit the file as follows

	Change From: 	BAT_CYC 14 
	 
	Change To:	BAT_CYC 28

  6. Ftp to the T3 and put the modified schd.conf file in the 
     /etc directory.

  7. Type "refresh -i "

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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