Ampex DFR900 User manual

' •.

DFR900 SERIES
DISK STORAGE DRIVE
OPERATION
AND MAINTENANCE MANUAL
3311546-01
AUGUST 1980
THE INFORMATION IN THIS MANUAL IS PROPRIETARY, AND IS NOT TO BE
REPRODUCED OR DISSEMINATED IN ANY FORM WITHOUT PRIOR WRITTEN
CONSENT OF AMPEX MEMORY PRODUCTS DIVISION.

LIST OF EFFECTIVE PAGES
Title Original
AOriginal
BBlank Original
ithru
ix Original
xBlank Original
1-1 thru
1-13 Original
1-14 Blank Original
2-1 thru
2-29 Original
2-30 Blank Original
3-1 thru
3-140 Original
4-1 thru
4-44 Original
5-1 thru
5-27 Original
5-28 Blank Original
6-1 thru
6-8 Original
Schematic Diagrams Original
A

TABLE OF CONTENTS
SECTION PAGE
GENERAL INFORMATION. ................................................... 1-1
1-1.
1-2.
1-5.
1-9.
1-10.
1-20.
General Description .
Features .
1-3. Key Features .
1-4. Other Features .
Customer-Selectable Characteristics .
1-6. Power Source .
1-7. Sector Versions .
1-8. ID Plugs .
Interface Capability .
Major Components .
1-11 .Electronics .
1-12. Power Supply .
1-13. Upper Positioning Assembly .
1-14. Sealed Fixed-Disk Module .
1-15. Spindle Drive Motor .
1-16. Air Supply and Filtering .
1
-1 7. Deck Plate .
1-18. Main Frame .
1
-1 9. Operator Control Panel .
Specifications
and Performance Characteristics .
1-21. Basic Specifications .
1-22. Environmental Limits (Operating) .
1-23. Environmental Limits (Shipping/Storage) .
1-24. Power Requirements .
1-25. Physical Characteristics .
1-26. Performance Characteristics .
1-27. Recoverable Data Errors .
1-28. Non-Recoverable Errors .
1-29. Seek Errors .
1-30. Cartridge .
1-31. Reliability .
1-32. Product Life .
1-33. Serviceability .
1-34. Preventive Maintenance .
1-35. Media Alignment .
1-36. Installation .
1-1
1-1
1-1
1-1
1-2
1-2
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-5
1-5
1-5
1-5
1-5
1-5
1-5
1-6
1-9
1-9
1-9
1-10
1-10
1-10
1-10
1-10
1-10
1-11
1-12
1-12
1-12
1-12
1-12
II
INSTALLATION AND OPERATION. ............................................. 2-1
2-1.
2-2.
2-3.
Scope .
Unpacking .
Installation and Checkout .
2-4. Space Allocation .
2-5. Height .
2-6.
Rear Clearance .
2-7. Installation Procedure .
2-8. Initial Checkout Procedure .
2-9. Cabling .
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-6
2-10

SECTION
III
ii
TABLE OF CONTENTS (Continued)
PAGE
2-10. Star and Daisy-Chain Cabling. ............................. 2-10
2-11. Notes on Cabling. ...................................... 2-14
2-12. Grounding................................................... 2-14
2-13. DC Ground............................................ 2-14
2-14. Frame Ground. ......................................... 2-14
2-15. Sector Number Selection. ................. .. .................... 2-15
2-16. Model Selection............................................... 2-15
2-17. Operation........................................................... 2-15
2-18. Operator Controls and Indicators. ................................. 2-15
2-19. Start/StopSwitch 2-15
2-20. Transition Indicator. ..................................... 2-15
2-21. Readylndicators 2-15
2-22. Write Protect. .......................................... 2-20
2-23. Cartridge-Missing Indicator. ............................... 2-20
2-24. Fault Indicator. ......................................... 2-20
2-25. Address ID Plug. ....................................... 2-21
2-26.
Disk Cartridge Access Door Latch. ......................... 2-21
2-27. Operating Instructions. ......................................... 2-21
2-28.
Power-Up............................................. 2-21
2-29.
Start................................................. 2-22
2-30. Write Protect. .......................................... 2-22
2-31. Stop................................................. 2-22
2-32. Power-Down ,......... 2-22
2-33. Remote Power Sequence. ................................ 2-22
2-34. Fault Operating Instructions. . . . . . .. ....................... 2-22
2-35. Disk Cartridge Handling and Storage. ....................... 2-23
2-36. Disk Cartridge Installation. ................................ 2-23
2-37. Disk Cartridge Removal. ................................. 2-23
2-38. Power Failure or Emergency Stop Cartridge Removal. . . . . . . . . . . 2-25
2-39. Maintenance Switches and Indicators. ........................... .. 2-25
2-40. Power Supply Indicators. ................................. 2-27
2-41. PRC (Processor) Board Switches ........................... 2-29
THEORY OF OPERATION. .................................................... 3-1
3-1. Introduction. ........................................................ 3-1
3-2. System Operation. ...................... .. ........................... 3-1
3-3. Input/Output (I/O) Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-4. Cabling. ..................................................... 3-2
3-5. Transmitters
and Receivers. ............................... 3-2
3-6. Terminators.. .......................................... 3-2
3-7.
Signal Cables ........................................ .. 3-2
3-8.
Signal Cable Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4
3-9. Signal Lines. ................................................. 3-6
3-10. Address
and Control Tag Lines. ........................... 3-6
3-11. Individual Lines. ........................................
3-10
3-1 2. Data and Clock Lines. ................................... 3-1 5
3-13.
Data Format and Data Control Timing ................... 3-16
3-1 4. Write Format Procedure. ................................. 3-1 9
3-15. Control
Timing. ....................... .. ............... 3-19
3-16. Major Assemblies. ................................................... 3-21

SECTION
TABLE OF CONTENTS (Continued)
PAGE
3-17. Printed Circuit Board Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 21
3-18. Disk Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-19. Spindle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-20. Fixed-Disk Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-25
3-21. Head Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-22. Rotary Actuator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-23. Air Filters. ............................................. 3-25
3-24. Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-25. Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-26. Linear Motor and Carriage Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-27. Velocity Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-27
3-28. Idler Assembly. ............................................... 3-27
3-29. Power Supply Assembly ........................................ 3-27
3-30. Auxiliary Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-31. Input Rectifier and Filter. ................................. 3-27
3-32. Surge Current Suppressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-33. Clock Pulse Oscillator. ................................... 3-30
3-34. Voltage-Sense Amplifier and Pulse-Width Converter. ........... 3-30
3-35. Driver Circuit. .......................................... 3-30
3-36. Power Switching. ....................................... 3-32
3-37. Output Current Sensing. ................................. 3-32
3-38. Overcurrent Protection. .................................. 3-32
3-39. Power-On Sequence. .................................... 3-32
3-40. Overvoltage Protection. .................................. 3-34
3-41. Momentary Power Failure Sensing Circuit. . . . . . . . . . . . . . . . . . . . 3-34
3-42. Remote-Off............................................ 3-34
3-43. Status Display. ......................................... 3-34
3-44. Functional Operations. ................................................ 3-38
3-45. Airflow...................................................... 3-38
3-46. Microprocessor Control Functions. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 3-38
3-47. Microprocessor Hardware. ................................ 3-38
3-48. Memory Address Assignments. ............................ 3-43
3-49. Program Interrupts. ........... .. . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-50. Input/Output Ports. ..................................... 3-45
3-51. Microprocessor Operational Flow Charts. ........................... 3-64
3-52. Power-Up Sequence. .................................... 3-67
3-53. Spindle Motor Start Sequence. ............................ 3-70
3-54. First Seek Lower ; . . . . . . . . . . 3-70
3-55. First Seek Upper.. .. . .. . . .. . .. .. .. .. . . . ... . . . .. . 3-74
3-56. Gain Select Lower ...................................... 3-74
3-57. Gain Select Upper ...................................... 3-74
3-58. Main Loop. .................... .. ..................... 3-79
3-59. Status Checks. ......................................... 3-79
3-60. Power-Down Sequence. ................................. 3-79
3-61. Spindle Motor Stop Sequence. ............................ 3-87
3-62.
Error Disposal. ................. .. ...................... 3-87
3-63.
Seek Interrupt. .............................. .. . . . . . . . . . 3-87
3-64. Command Interrupt. ..................................... 3-87
3-65.
Seek Command. ....................................... 3-96
3-66. RTZ Lower Command ................................... 3-96
3-67. RTZ Upper Command .. ................................. 3-96
iii

SECTION
TABLE OF CONTENTS (Continued)
PAGE
3~68. Start/Stop Operations .
3-69. Spindle Start .
3-70. Sequential Start-Up, Daisy-Chain Configuration .
3-71 .Spindle Rotation Time Check .
3-72. Spindle Stop .
3-73. Door Latch Unlocking , .
3-7 4. Seek Operation .
3-75. General .
3-76. Basic Servo Operation .
3- 77 . Seek Operation Sequence .
3-78. Servo Data .
3-79. Seek Signal Descriptions .
3-80. Track Servo Signal
(TSS) .
3-81. End of Travel (Guardband) .
3-82. Cylinder Pulse .
3-83. Velocity .
3-84. On Cylinder .
3-85. SPIN-DL .
3-86. Sync Data .
3-87. Desired Velocity .
3-88. Power Off .
3-89. Dibit , .
3-90. Read/Write Operations .
3-91. Write Operation .
3-92. Read Operation .
3-96
3-96
3-101
3-101
3-101
3-103
3-103
3-103
3-103
3-103
3-105
3-109
3-109
3-110
3-110
3-111
3-111
3-116
3-116
3-116
3-116
3-116
3-116
3-124
3-127
IV
iv
MAl NTENANCE ............................................................ 4-1
4-1. Introduction. ........................................................ 4-1
4-2. Maintenance Precautions. .............................................. 4-1
4-3. Safety Precautions. ............................................ 4-1
4-4. Equipment Precautions. ......................................... 4-1
4-5. Maintenance Tools
and Expendables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-6. Maintenance Intervals. ................................................ 4-1
4-7. Preventive Maintenance. ...............................................
4-3
4-8. Makeup Filter Cleaning 4-3
4-9. Prefilter Cleaning. ............................................. 4-3
4-10. First Filter Removal and Installation. ............................... 4-3
4-11. Data Head and Servo Head Cleaning. ............................. 4-5
4-12. Cleaning of R-Carriage Rails and Bearings. .......................... 4-5
4-13. Corrective Maintenance. ............................................... 4-7
4-14. Top Cover Removal and Installation ............................... 4-7
4-15. Bottom Cover Removal and Installation ; . . . . . . . . . . . 4-7
4-16.
Data Head Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-17. Servo Head Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-9
4-18. Module Removal and Installation. ................................. 4-10
4-19. Brake Assembly Removal and Installation. .......................... 4-12
4-20. Motor Assembly Removal and Installation. .......................... 4-14
4-21. Idler Assembly Removal and Installation. ........................... 4-14
4-22. Spring Earth Assembly Removal and Installation. ..................... 4-15
4-23. Card Cage Assembly Removal and Installation. ...................... 4-15

SECTION
v
VI
TABLE OF· CONTENTS (Continued)
PAGE
4-24. Power Supply Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . .. . . 4-16
4-25. Fan Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-26. Pulley Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-2 7. R-Carriage Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . 4- 20
4-28. R-Carriage Load Rail and Fixed Rail Removal and Installation. ........... 4-22
4-29. R-Carriage Main Rail Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . 4-22
4-30. Velocity Sensor Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . 4-23
4-31. Sensor Rod Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-32. Linear Motor Magnet and Coil Removal and Installation. . . . . . . . . . . . . . . . 4-24
4-33. Solenoid Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-34. PCB-FTP Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-35. PCB-PAU Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4-36 .. PCB PAL Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4-37. Relay Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4-38. Drive Tests and Adjustments. ........................................... 4-28
4-39. Head Alignment. .............................................. 4-28
4-40. Precautions............................................ 4-29
4-41. CE Cartridge. ........................................ .. 4-29
4-42. Head Alignment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-29
4-43. PCB Adjustment. ............................................ .. 4-34
4-44. Confirmation Test After PCB Replacement. .......................... 4-34
4-45. Confirmation Test After Power Supply Replacement. . . . . . . . . . . . . . . . . . . 4-35
4-46. Confirmation Test After Head Replacement. ......................... 4-36
4-47. Confirmation Test After Module Replacement. ....................... 4-36
4-48. Manual Head Loading. ......................................... 4-36
4-49. Read/Write Adjustments ........................................ 4-37
4-50. Servo Upper Adjustment. ....................................... 4-38
4-51. Servo Lower Adjustment. ....................................... 4-39
4-52. Maintenance Aids. ................................................... 4-40
4-53. Maintenance Switches and Indicators. ............................. 4-40
4-54. Operator Indicators ............................................ 4-44
4-55. Power Supply Indicators. ....................................... 4-44
PARTS LIST ............................................................... 5-1
5-1 .General. ........................................................... 5-1
MAINTENANCE DRAWINGS. ................................................. 6-1
6-1 .Introduction. ........................................................ 6-1
6-2. List of Drawings. .................................................... 6-1
6-3. Interconnection Symbology. ............................................ 6-2
6-4.
General Abbreviations. ..................................... .. . . . . . . . . . 6-2
6-5. Signal Annotation. ................................................... 6-2
6-6. Functional Symbology. ................................................
6-4
6-7. Signal Name. ....................................................... 6-5
6-8. Digital Integrated Circuits. ............................................. 6-6
v

FIGURE
1-1
1-2
1-3
1-4
1-5
1-6
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-24
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
vi
LIST OF ILLUSTRATIONS
DFR Configuration .. , .
Major Components .
Head Number for SMD Interface .
Head Number for Independent Seek .
Disk Cartridge .
Fixed and Removable Modules .
Dimensional View .
Detail Dimensions .
Bracket
and Rack in Rear Side Fitting .
Rail and Bracket in Rear Side Fitting .
Fore Side Fitting .
Rail and Unit. .
Rail and Unit Sectional View .
Rail Bracket Detail. Side View .
Rail Bracket Detail, Sectional View .
Front
Panel .
Upper Carriage Stopper .
Lower Carriage Stopper .
100 V/1 20 VPower AC Cable .
230 VAC Power Cable .
Read/Write and Control Cable Connectors .
Star Cable Configuration .
Daisy-Chain Configuration .
DC and Frame Grounds .
Sector Number Selection .
Model Selection .
Operator Controls and Indicators .
Disk Cartridge Installation
and Removal .
Maintenance Switches and Indicators .
Rear Power Supply Indicators .
Typical Ribbon-Cable Control or Status Transmission
Line .
Typical Ribbon-Cable Data or Clock Transmission Line .
Tag and Bus Timing .
Typical Timing with Address Mark .
Index
and Sector Timing .
SVU Board Jumper Pins .
Open Cable Detect Circuit .
Logic Number Select Code
and Timing Diagram .
Write
Data and Servo Clock Timing .
Read Data Timing .
Fixed-Sector Format .
Variable-Sector Format .
Control Timing .
Functional Block Diagram .
Major Assemblies .
Power Supply Block Diagram .
Auxiliary Power Supply .
Input Rectifier
and Filter .
Surge Current Suppressor .
PAGE
1-2
1-4
1-7
1-7
1-11
1-13
2-2
2-3
2-4
2-4
2-5
2-5
2-6
2-7
2-8
2-8
2-9
2-9
2-11
2-11
2-12
2-13
2-13
2-14
2-16
2-17
2-21
2-24
2-27
2-29
3-5
3-5
3-7
3-9
3-11
3-12
3-14
3-15
3-16
3-16
3-17
3-18
3-20
3-22
3-26
3-28
3-29
3-30
3-31