Overland Storage NEO 8000 User manual

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 1 of 7
IMPORTANT: Overland Storage requires that all NEO
Series parts be removed and replaced by an Overland
Storage authorized service provider. Improper installation may
result in damage which voids existing warranties.
This document describes how to remove and replace the
Shuttle Signal/Power Cable assembly in a NEO 8000
Library. This kit also contains mounting hardware
necessary to install this assembly.
CAUTION: Due to the critical importance of this part, it is
absolutely imperative that these instructions be followed
exactly.
If you have any questions or concerns, contact Overland
Technical Support:
•1-877-654-3429 (toll-free U.S. & Canada)
•[phone] (Europe)
•[phone] Option 5 (International)
WARNING: The GUI touch screen does not completely
shut off NEO SERIES system power. To reduce the risk
of electric shock or damage, remove both power cords.
CAUTION: Do not remove any of the gold-colored Kapton
tape from the cable or cable assembly. It properly
positions the cable during library operation.
Unpacking the Spare
NOTE: Do NOT cut the plastic holding the shuttle cable in
place; the same packaging is used to return the old cable.
Carefully unpack and verify that you have all the parts:
•Shuttle Signal/Power Cable assembly
(with Spooler top piece propositioned)
•One panhead 4-20x1/2 spooler screw
•Two flathead M4x6 bracket screws
•Two Cable ties
•Clip retainer
•Plastic-coated clamp
•These instructions
A #1 or #2 Phillips screwdriver is also needed (depending
on the NEO version). A tube of Loctite 222 (or equivalent
product) is also strongly recommended.
Electrostatic Discharge Information
A discharge of static electricity can damage micro-circuitry
or static-sensitive devices. To help prevent electrostatic
damage, observe the following precautions:
•Transport and store items in static-safe containers.
•Keep electrostatic-sensitive parts in their containers.
•Use properly-grounded tools.
•Make sure you are always properly grounded.
•Keep the work area free of non-conductive materials.
•Avoid touching pins, leads, or circuitry.
Verify Cable Assembly
CAUTION: If the cable is missing the spooler head
(Figure 1), DO NOT USE it. Contact Overland Technical
Support immediately.
Verify you have the correctly assembled part:
Figure 1. Shuttle Cable Assembly
NEO 8000 Library
Shuttle Signal/Power Cable
Remove & Replace Instructions
Overview & Notes
NEO-8162
NEO-8162
Power CableSignal Cable
SPI
Shuttle Plugs
Spooler
Cable
Bracket
(Dual)
Metal Flex Guide
Stabilizers
Plugs
Head

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 2 of 7
Power Down the Library
1. On the front GUI panel, press Power to turn the
library OFF.
The shuttle/track assembly moves to the library floor as
the unit shuts down.
NOTE: If the library is non-functional, wait until the shuttle/
track assembly drifts to the bottom automatically.
2. At the rear (Figure 2), in the bottom left corner, turn
OFF the circuit breakers.
Figure 2. Location of Circuit Breakers in Rear
3. Remove and retain all power cords.
Provide Access to Z-Axis Assembly
WARNING: To prevent injury due to the weight of a
loaded drawer, DO NOT fully remove the media
drawers. Leave them in the open position.
1. Verify there is access to the library’s left side.
IMPORTANT: If access through the left panel is not
available, this procedure can still be used by
accessing the component from the front and rear. Go to
the Overland Support FAQ web site to obtain the NEO
8000 Limited Access Procedure.
2. Remove and retain the screws securing the left side
panel, and remove the panel.
3. Open the left door of the library.
4. From the left side, at the back of the bottom-left media
drawer, press the door’s latch release (Figure 3) and
push the media drawer forward.
Figure 3. Media Drawer Latch Release, Rear View
5. From the front, pull out the bottom-left media drawer
until it latches in the open position.
6. Repeat Steps 4–5 for the middle-left media drawer.
Disconnecting Rotary SPI Cables
1. At the rear of the library, locate the Rotary SPI board
(Figure 4).
Figure 4. Rotary SPI Board Location (Rear View)
2. Disconnect cables and wiring bundles from the
connectors on the PWA (Figure 5 on page 3):
•Disconnect the Backplane wire bundle from J1
freeing the shuttle cables.
•Disconnect the Power wire bundle from J2.
NOTE: Move the wiring bundles off to the side.
•Disconnect the Power cable from J3.
•Disconnect the Signal Controller cable from J4.
Preparing the Library
Circuit Breakers
NEO-8148
Override Latch
Removing the Old Cable Assembly
NEO-8141

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 3 of 7
Figure 5. Rotary SPI Board in Rear Z-Axis Assembly (Rear View)
3. Remove the metal retainer clip holding the shuttle
cables to the Rotary SPI bracket (Figure 6).
Figure 6. Key Components on Rear Z-Axis Assy.(Front View)
4. Carefully cut the cable ties holding the shuttle cables
to the Rotary SPI bracket.
5. Remove the two M4x6 screws holding the metal flex
guide to the rear Z-axis bracket.
Disconnecting Shuttle Cables
1. On the shuttle, locate the Shuttle PWA (Figure 7) and
release the shuttle cables:
a. If a cable clamp is installed, release the clamp.
b. Disconnect the Power cable from the J2 connector.
c. Disconnect the Signal Controller cable from the
J4 connector.
Figure 7. Shuttle PWA and Cables (Front View)
2. Use the Phillips screwdriver, unscrew and detach the
spooler head leaving the cables attached (Figure 8).
Figure 8. Removing the Cable from the Spooler Head
NOTE: The two lower Spooler components can easily slip off
the spindle. Be sure that both the lower components remain
in place.
3. Place the old shuttle cable assembly inside the
plastic sheet on the center cardboard brace from the
packaging and fold the arms down to lock it in place.
NOTE: Use the original box and packaging to return the old
shuttle cable.
NEO-8154
Rotary
SPI Board
Backplane
Wires (J1)
Power
Wires (J2)
Signal
Cables (J4)
Power
Cable (J3)
Flex Chain
Retainer
Clip
M4x6 Screws
Cable Ties
Rotary SPI
Bracket
NEO-8157
Spooler
Power
Connector (J2)
Cable Clamp
Signal Controller
Connector (J4)
Spooler Head
Spooler
Bottom
(2 Pieces)
Metal Tab
Phillips Screw
Cable
Assembly

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 4 of 7
CAUTION: The cable assembly in some older NEO
libraries may have been routed differently. Follow the
instructions below EXACTLY to route the new cable.
Attach Assembly to Rear Z-Axis Bracket
1. If available, apply Loctite 222 (or equivalent) onto the
two supplied M4x6 screws.
2. Use the two screws to attach the new cable assembly
to the rear Z-axis bracket (Figure 9).
NOTE: The bend in the cable behind the screws is held in
place with Kapton tape. Leave the bend and tape in place.
Figure 9. Attach Cable Assembly to Z-Axis Bracket
3. Connect the two cable ties together by inserting the
end of one into the head of the other just far enough for
the teeth to engage.
4. Position the cables between the screw plates (Figure 9),
and secure it in the corner with a cable tie assembly.
5. Secure the cable assembly to the bracket (Figure 9):
a. Position the cable fold on the bracket near the SPI
board with the cable flat against the bracket.
b. Hook the metal clip retainer onto the bracket
securing the cables to it.
6. In this order with the cables cleanly looped over the
bracket (Figure 10 with steps labeled), attach the
cables to the Rotary SPI:
a. Connect the Signal Controller cable to J4.
b. Connect the shuttle Power cable to J3.
c. Placing the small Power wiring over the shuttle
cables to hold them in place, connect it to J2.
d. Placing the Backplane wiring also over the shuttle
cables, connect it to J1.
e. Gently pull the cable loop located above the retainer
clip on the Rotary SPI bracket upwards until the
cables are fully inside the wiring bundles with no
slack at the connectors.
CAUTION: Verify that the shuttle flex cable does NOT
extend beyond the edge of the Flex Chain.
Figure 10. Rotary SPI Shuttle Cable Connections
Attach Spooler Head
1. Verify that the two bottom spooler pieces are still
on the shuttle spindle.
2. Slide the spooler head onto the bottom pieces,
aligning the flat side slot with the metal tab (Figure 8
on page 3).
CAUTION: Be sure there are no other twists in the
cable between the metal guide and the spooler
(Figure 11). If necessary, slide the shuttle to the
front of the track plate to extend the flex cable.
Figure 11. Final Position of Cable Assembly
3. Use the supplied panhead Phillips screw to reattach
the spooler head to the shuttle spindle.
CAUTION: To prevent damage to the plastic spooler
head, do not overtighten the panhead screw.
Installing the New Cable Assembly
Align cable
between the
screw plates
M4x6 Screw
M4x6 Screw
Cable
Screw Plates
Tie
Clip
Retainer
NEO-8154
Verify Cables Are
Secured Behind
Wire Bundles
(e) Pull Up Gently To
(d) Backplane
Wires (J1)
(c) Power
Wires (J2)
(a) Signal
Cables (J4)
(b) Power
Cable (J3)
Flex Chain
Any Remove Slack
Verify Flat & No Twists

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 5 of 7
Connect the Cables to the PWA
Attach the cables from the spooler to the shuttle PWA
(also see the photo sequence on page 7):
1. With the plastic-coated clamp arm pointing out,
attach it to the shuttle just above the bar code reader
next to the Shuttle PWA (Figure 12 & Figure 17).
If an older wire clip is there, remove it first.
Figure 12. Attach the Clamp
2. Loop and connect the signal controller cable to J4
(Figure 13 & Figure 18).
Figure 13. Connect the Signal Controller Cable
3. Connect the shuttle power cable to J2:
a. With the Power cable flat against the Signal cable,
insert the Power cable through the Signal cable loop
(Figure 19).
b. Loop the Power cable upwards.
c. Carefully, without bending the cable, insert the
Power connector into J2 (Figure 14 & Figure 20).
d. Verify the following:
•The first bend on the Power cable is near the top
of the Signal plug.
•The Power cable is tilted at a 45° angle inside the
Signal cable loop with the high side next to the
Signal plug,
•There is no bend in the cable where the plug
enters the Power connector.
Figure 14. Connect the Power Cable
4. Bend the clamp around both cables (Figure 15 &
Figure 21):
a. Gather both cables together next to the clamp so
that they are aligned.
b. Prebend the clamp 60° about 1/3 down the shaft.
c. Fold the clamp over the cables and finish bending
the top third around the cables.
d. Position the clamp above the PWA and press it
against the shuttle front.
Figure 15. Connecting the Cable to the Shuttle PWA
5. Pull gently on the cables between the clamp and the
spooler until the cable loops are flush with the bar
code reader (Figure 16 & Figure 22).
Figure 16. Flex Cable Must NOT Extend Beyond Reader
NEO-8152
Attach Here
Move arm
to 90°
Bar Code Reader
NEO-8155
Loop
Connect
NEO-8156
Connect
Loop
NEO-8157
Fold & Clamp
Bar Code Reader
Bar Code Reader

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 6 of 7
After you install the shuttle cable assembly, verify the
installation and test the library.
Examine Cable Assembly
CAUTION: Due to the high-speed movement of this
assembly, it is critical that none of the cables stick out in
a way that may cause them to come into contact with
stationary items.
1. Visually examine and manually move the cable
assembly to verify that the cables do not catch on
anything as the shuttle assembly or track moves.
•The cables at the Rotary SPI should not extend past
the flex chain.
•The cables at the shuttle should not extend past the
edge of the bar code reader (Figure 16 on page 5).
2. At the rear, check the Z-axis cable alignment, the loop
in the cable, and the metal clip retainer.
3. Make sure the cable assembly metal flex guide and
bracket shape was not altered during installation.
CAUTION: The metal flex guide should be parallel to
the side of the library. Verify that the shuttle doesn’t
hit the guide as it moves up and down the track.
Power On Self Test (POST)
1. Close the media drawers.
2. Shut the front left door.
3. Plug the power cords back in.
4. Turn on the circuit breakers.
NOTE: If the bar code reader is not detected, recheck the
cable connections and reapply power to the unit.
5. Observe the POST process to verify the installation:
WARNING: Use extreme caution in making the
observations listed. The robotics move very quickly.
•Watch the shuttle assembly and track movement.
•Make sure that nothing interferes with the cable
assembly through its full range of motion.
NOTE: If problems occur, contact Overland Technical Support.
6. Using the retained screws, reattach the left panel to
the library.
IMPORTANT: If following the NEO 8000 Limited
Access Procedure, this is the point to reinstall the
library panels and components previously removed.
Return Removed Parts to Overland
1. Place the removed parts in the replacement parts box
you saved.
2. Follow directions included with the box for returning
parts to Overland Storage.
Power On and Test the Library
Additional Help
You can get additional technical support on the Internet at http://support.overlandstorage.com, or call
1-877-654-3429 (toll-free U.S. & Canada), [phone] (Europe), or [phone] Option 5 (International).

Part Number 10400233-101 04/2009 ©2005-2009 Overland Storage, Inc. Page 7 of 7
Figure 17. Secure Plastic-Coated Clamp to Shuttle
Figure 19. Insert Power Cable Through Signal Cable Loop
Figure 21. Fold & Press Clamp Arm Around Cables; Pull Excess
Figure 18. Loop & Insert Signal Controller Cable Into J4
Figure 20. Loop & Insert Power Cable Into J2
Figure 22. Cables Flush with Bar Code Reader
Pictorial of Shuttle Cable Connection Steps
1
3
5
2
4
6Flex Cables Flush With Bar Code Reader