Qualstar TLS-4000 Operating manual

The Tape Library ExpertsTM
TLS-4000
Technical
Service Manual
501380 Rev. B

Important Manual/Firmware Revision Information
This manual and the operating firmware for the TLS are revised periodically as the
product is improved. This manual was revised to correspond with the firmware ver-
sion indicated below. Do not use this manual with different part numbers or prior ver-
sions of the firmware. Check with Qualstar Technical Support about use of this man-
ual with newer firmware.
Manual Corresponding Firmware
TLS-4000 Technical Service Manual
501380 Rev. B, April 14, 2004
TLS Executive Firmware
700105 Version 2.21
Copyright Notice
Copyright©2004 by Qualstar Corporation — All Rights Reserved
Information contained in this document is copyrighted by Qualstar Corporation. It is
intended for use by Qualstar’s customers and prospective customers to evaluate, inte-
grate, operate and maintain Qualstar products. Customers and prospective customers
may reproduce this document as needed for these uses. Reproduction in whole or in
part for any other use or by any other party is prohibited without prior written per-
mission from Qualstar Corporation.
Every effort has been made to keep the information contained in this document cur-
rent and accurate as of the date of publication or revision. However, no guarantee is
given or implied that the document is error-free or that it is accurate with regard to
any specification. Qualstar reserves the right to modify product designs and specifica-
tions without notice.
Qualstar and the Qualstar logo are registered trademarks of Qualstar Corporation.
Other trademarks are the property of their respective owners.
Inventory Sentry is a trademark of Qualstar Corporation.
Notices
Qualstar products are covered by one or more of the following patents:
6,163,139 and 6,560,061. Other patents pending.
Qualstar equipment is manufactured from new parts, or new and used parts. In some
cases, Qualstar equipment may not be new and may have been previously installed.
Regardless, Qualstar’s warranty terms apply unless the equipment is specifically
identified by Qualstar as “used” or “refurbished”.
501380 Rev. B i

This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to pro-
vide reasonable protection against harmful interference when the equipment is oper-
ated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruc-
tion manual, may cause harmful interference to radio communications. Operation of
this equipment in a residential area is likely to cause harmful interference in which
case the user will be required to correct the interference at his own expense. Shielded
cables are required for this device to comply with FCC Rules. Use shielded cables
when connecting this device to others.
European Union Directive 89/336/EEC and Standard EN55022
(Electromagnetic Compatibility)
Warning
This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.
Technical Support Information
The best source for service-related information is your system reseller. Alternately,
the Qualstar Technical Support Department can be reached Monday through Friday,
between the hours of 7:30 A.M. and 4:30 P.M. Pacific Time, at:
Qualstar Corporation
3990-B Heritage Oak Court
Simi Valley, CA 93063
Attn: Technical Support
Fax: [phone]
Phone: [phone]
Monday – Friday 7:30 a.m. to 4:30 p.m. PST
After hours support: [phone] or [phone]
E-Mail [email protected]
E-Mail: [email protected]
Web: www.qualstar.com
ii 501380 Rev. B

Table of Contents
1. Introduction................................................................................................................... 1-1
1.1 Who Should Read This Manual................................................................................... 1-1
1.2 Important Safety Information ..................................................................................... 1-2
1.3 Lithium Battery............................................................................................................ 1-3
2. Description and Theory of Operation ..................................................................... 2-1
2.1 Model Identification ..................................................................................................... 2-1
2.2 General Description ..................................................................................................... 2-2
2.2.1 Motion Systems ..................................................................................................... 2-2
2.2.2 Sensors ................................................................................................................... 2-3
2.2.3 Handler Solenoid................................................................................................... 2-5
2.2.4 Barcode Reader...................................................................................................... 2-5
2.2.5 Barcode Labels ...................................................................................................... 2-5
2.3 Barcode Labels Usage .................................................................................................. 2-5
2.4 Component Identification ............................................................................................ 2-6
2.4.1 TLS Models ............................................................................................................ 2-7
2.4.2 Handler .................................................................................................................. 2-9
2.4.3 I/O Port Assembly ................................................................................................. 2-9
2.4.4 Field-Replaceable Units (FRUs)......................................................................... 2-10
3. The Menu System ......................................................................................................... 3-1
3.1 Using the Menu Control Keys ..................................................................................... 3-1
3.1.1 The MENU Control Key ....................................................................................... 3-1
3.1.2 The (UP) and (DOWN) Control Keys........................................................... 3-1
3.1.3 The ENTER Control Key ...................................................................................... 3-2
3.1.4 The EXIT Control Key .......................................................................................... 3-3
3.1.5 The CALL Control Key ......................................................................................... 3-3
3.1.6 The (Daisy) Key and I/O Port Operation ........................................................ 3-3
3.2 The Top Menu............................................................................................................... 3-5
3.3 Menu Elements............................................................................................................. 3-6
3.3.1 Menu Items............................................................................................................ 3-6
3.3.2 Values..................................................................................................................... 3-7
3.3.3 Location Designators ............................................................................................ 3-8
3.3.4 Editing Values ....................................................................................................... 3-8
3.4 The Menu Hierarchy .................................................................................................. 3-11
3.5 Displaying the TLS Firmware Revision ................................................................... 3-12
3.6 Alerts ........................................................................................................................... 3-12
3.7 Dynamic Menus and Menu Items ............................................................................. 3-12
4. Maintenance Menu....................................................................................................... 4-1
501380 Rev. B iii

4.1 Maintenance Menu....................................................................................................... 4-2
4.1.1 SN........................................................................................................................... 4-2
4.2 Maintenance\Display Log Menu ................................................................................ 4-3
4.2.1 Introduction ........................................................................................................... 4-3
4.2.2 Data Logging – General Description.................................................................... 4-4
4.3 Maintenance\Display Log\Display\Entry Menu ..................................................... 4-5
4.4 Maintenance\Display\Prevents Status Screen......................................................... 4-6
4.5 Maintenance\Display Revision Status Screen .......................................................... 4-6
4.6 Maintenance\Display Stats. Status Screen ............................................................... 4-7
4.7 Maintenance\Display Voltage Status Screen ............................................................ 4-9
4.8 Maintenance\Test Inventory Status Screen.............................................................. 4-9
4.9 Maintenance\Test Keyboard Status Screen ............................................................ 4-10
4.10 Maintenance\Test LC Display Status Screen ...................................................... 4-11
5. The Private Menu ......................................................................................................... 5-1
5.1 Introduction .................................................................................................................. 5-2
5.2 Security Locks............................................................................................................... 5-3
5.2.1 Door Lock ............................................................................................................... 5-3
5.2.2 Master Lock ........................................................................................................... 5-3
5.2.3 Disabling the Master Security Lock .................................................................... 5-3
5.3 Enabling the Private Menu ......................................................................................... 5-4
5.3.1 Access ..................................................................................................................... 5-4
5.3.2 Setting a Password................................................................................................ 5-5
5.3.3 Clearing the Password .......................................................................................... 5-7
5.4 The Private Menu......................................................................................................... 5-8
5.4.1 Private\CALIBRATE Command ......................................................................... 5-8
5.4.2 Private\CLEAR ACCESS Command .................................................................. 5-9
5.4.3 RESET SCSI BUS Command............................................................................... 5-9
5.4.4 The Private\Calibration Data Status Screen ................................................... 5-10
5.4.5 The Private\Carousel Menu .............................................................................. 5-12
5.4.6 The Private\Configuration Menu ...................................................................... 5-14
5.4.7 The Private\Defaults Menu ............................................................................... 5-14
5.4.8 The Private\Configuration\SCSI Menu ........................................................... 5-15
5.4.9 The Private\Display A/D Status Screen ........................................................... 5-16
5.4.10 The Private\Display Locations Menu ............................................................... 5-17
5.4.11 The Private\Display Positions Status Screen................................................... 5-19
5.4.12 The Private\Display Sensors Status Screen..................................................... 5-20
5.4.13 The Private\DriveBay Menu ............................................................................. 5-21
5.4.14 The Private\Executive Menu............................................................................. 5-22
6. Troubleshooting............................................................................................................ 6-1
6.1 Power Up and Initialization Failures ......................................................................... 6-3
iv 501380 Rev. B

6.2 Operation Failures ..................................................................................................... 6-10
6.3 Calibration Failures ................................................................................................... 6-14
7. Field–Replaceable Units (FRUs)............................................................................... 7-1
7.1 Introduction .................................................................................................................. 7-1
7.2 Field-Replaceable Units (FRUs).................................................................................. 7-2
7.3 Required Tools and Materials ..................................................................................... 7-3
7.4 Top and Side Panels ..................................................................................................... 7-4
7.5 Carriage Assembly ....................................................................................................... 7-6
7.6 Carriage PCBA ........................................................................................................... 7-16
7.7 Barcode Reader........................................................................................................... 7-18
7.8 Air Filter and Fan Assembly ..................................................................................... 7-21
7.9 I/O Port Assembly....................................................................................................... 7-29
7.10 I/O Port PCBA ......................................................................................................... 7-31
7.11 Switch Bracket Assembly (Front Panel) ............................................................... 7-33
7.12 Handler Power Supplies......................................................................................... 7-36
7.13 Tape Drive Power Supplies .................................................................................... 7-42
7.14 Executive PCBA...................................................................................................... 7-44
7.15 Drive Bay PCBA...................................................................................................... 7-53
7.16 Carousel PCBA........................................................................................................ 7-55
7.17 Carousel Motor........................................................................................................ 7-57
7.18 SCSI High Voltage Differential Adapter PCBA ................................................... 7-61
7.19 Q-Link...................................................................................................................... 7-63
7.20 After-maintenance Test Procedures ...................................................................... 7-65
8. Firmware Updating ..................................................................................................... 8-1
8.1 Firmware Replacement................................................................................................ 8-1
8.2 Determining the Installed Hardware and Required Firmware ................................ 8-1
8.2.1 Firmware Update via the SCSI of Fibre Channel Interface .............................. 8-3
8.3 Firmware Update via Q-Link ...................................................................................... 8-5
8.4 Firmware Update via Q-Conn ..................................................................................... 8-8
8.4.1 RS-232 Cable Wiring............................................................................................. 8-8
8.4.2 RS-232 Serial Communications Parameters ....................................................... 8-8
8.4.3 User Terminal Software Setup Example............................................................. 8-8
8.4.4 VT100 Terminal Emulation................................................................................ 8-10
8.4.5 Remote Library Command Mode ....................................................................... 8-12
8.4.6 Xmodem Firmware Download <xdl> ................................................................. 8-12
8.4.7 Procedure for Replacing the Flash Memory I. C. on Executive I Boards ........ 8-14
8.4.8 Procedure for Replacing the Flash Memory I.C. on Executive III or IV
Boards .................................................................................................................. 8-16
8.4.9 Procedure for Replacing the Flash Memory I.C. on Drive Bay Boards ........... 8-17
9. TLS Expansions ............................................................................................................ 9-1
501380 Rev. B v

9.1 Introduction .................................................................................................................. 9-1
9.2 Model Expansions......................................................................................................... 9-2
9.2.1 Installing a Model Expansion Kit ........................................................................ 9-2
9.2.2 Entering the Update Password .......................................................................... 9-10
9.2.3 Reconfiguring the Model Number ...................................................................... 9-11
9.2.4 Recalibrating the Unit ........................................................................................ 9-12
9.2.5 Clearing the Password ........................................................................................ 9-12
9.3 Barcode Reader........................................................................................................... 9-12
9.3.1 Required Parts and Tools ................................................................................... 9-12
9.3.2 Barcode Reader Installation............................................................................... 9-13
9.4 I/O Port........................................................................................................................9-16
9.4.1 Required Parts and Tools ................................................................................... 9-16
9.4.2 I/O Port Installation............................................................................................ 9-16
10. System Interconnect Diagram ................................................................................ 10-1
vi 501380 Rev. B

1. Introduction
1.1 Who Should Read This Manual
This Technical Service Manual is for Tape Library System (TLS) service personnel. It
describes the Maintenance Menu, the Private Menu and Field Replacement Units
(FRU's). It also contains troubleshooting procedures, instructions for removing and
replacing FRU's and after–maintenance testing procedures. Finally, Chapter 9 con-
tains the System Interconnect diagram.
The following topics are covered in the TLS-4000 Installation and Operation manual
(Qualstar document number 501370):
• Unpacking Instructions
• Control Panel
• Menu System
• System Configuration
• System Operation
• Preventative Maintenance
• Repacking Instructions
For information about the SCSI interface, or other information outside the scope of
this manual, please refer to the appropriate documents listed below.
Subject Document
Qualstar
Document
Number
SCSI Command Information TLS-4000 SCSI-2 Interface Manual 500523
Installation and Operation TLS-4000 Installation and Operation Manual 501370
Specifications TLS-4000 Product Specification 500563
Fibre Channel Option Fibre Channel Option Installation and Operation Manual 501440
Supported Tape Drives Product Information Note PIN-014
Approved Data Cartridges Product Information Note PIN-038
Barcode Label Specifications Product Information Note PIN-040
SCSI-2 ANSI X3.131-1994 N/A
SCSI SPI-2 Specifications ANSI X3.302-1998
SCSI Parallel Interface-2 (SPI-2) N/A
SCSI-3 ANSI X3.253:199X
and Amendment AM1 to X3.253.1995 N/A
Table 1-1 Applicable Documents
501380 Rev. B Introduction 1-1

Although Qualstar has made every effort to insure the accuracy of the information
contained in this manual, no guarantee is expressed or implied that the manual is
error-free. Qualstar reserves the right to make changes at any time without prior no-
tification.
The Qualstar TLS-4000 Series of Tape Libraries are sophisticated, state-of-the-art
computer peripherals. They should only be serviced by a competent service technician
who is experienced with the operation and maintenance of tape libraries, and only af-
ter reading and understanding this manual and the TLS-4000 Installation and Opera-
tion Manual.
1.2 Important Safety Information
All of the operating instructions and maintenance procedures in Qualstar manuals
must be followed to prevent personal injury or damage to the equipment. In the inter-
ests of safety, there are two kinds of warnings used in Qualstar documents, as shown
below.
DANGER
PERSONAL INJURY MAY RESULT IF YOU DO NOT FULLY COMPLY WITH THE
HANDLING, OPERATING, OR SERVICE INSTRUCTIONS FOUND IN A DANGER
PARAGRAPH.
GEFAHR
UNSACHGEMAESSE BENUTZUNG, BEDLENUNG ODER RAPARATUR AUF-
GRUND VON NICHTBEGEFAHR DER SICHERHEITSANWEISUNG KANN ZU VER-
IET-ZUNGEN FUEHREN.
CAUTION
EQUIPMENT DAMAGE OR LOSS OF DATA may result if you do not fully comply
with the handling, operating, or service instructions found in a CAUTION para-
graph.
1-2 Introduction 501380 Rev. B

In addition, useful information and tips may be found throughout the document in the
following formats:
NOTE
SPECIAL ATTENTION to explanatory statements found in a NOTE paragraph will help you avoid
mistakes and/or save time.
NOTICE
A NOTICE box contains additional important information.
1.3 Lithium Battery
Please observe the following information when repairing the unit.
DANGER
U9, A DALLAS SEMICONDUCTOR CORPORATION DS1225AB OR A SGS-
THOMPSON MICROELECTRONICS M48258X IC ON THE EXECUTIVE PCBA
CONTAINS AN INTEGRAL LITHIUM BATTERY. AN EXPLOSION DANGER EXISTS
IF THE IC IS INCORRECTLY REPLACED. REPLACE THE IC ONLY WITH THE SAME
PART NUMBER, OR AN EQUIVALENT DESIGNATED BY THE MANUFACTURER.
DISPOSE OF THE USED IC ACCORDING TO THE MANUFACTURER'S INSTRUC-
TIONS.
GEFAHR
DER U9, EIN DALLAS SEMICONDUCTOR CORPORATION DS1225AB ODER EIN
A SGS-THOMPSON MICROELECTRONICS M48258X IC AUF DEM EXECUTIVE
BOARD ENTHAELT EINE INTEGRIERTE LITHIUM BATTERIE. WENN DIESE UN-
SACHGEMAESS AUSGETAUSCHT WIRD, BESTEHT EXPLOSIONS GEFAHR. DER
IC DARF NUR DURCH EINEN ARTIKEL MIT DER SELBEN ARTIKELNUMMER,
BZW, MIT EINEM VERGLEICHBAREN ARTIKEL LAUT HERSTELLER ANGABE ER-
SETZT WERDEN. DIE ENTSORGUNG DES ALTEN IC’S DARF NUR GEMAESS HER-
STELLERANGABEN ERFOLGEN.
501380 Rev. B Introduction 1-3

2. Description and Theory of Operation
2.1 Model Identification
4210, 4212, 4222 4420, 4440, 4480 4660, 46120
Figure 2-1 TLS-4000 Models
TLS-4000 Feature/Model 4210 4212*4222*4420 4440 4480 4660 46120
Maximum number of tape drives 2 2 2 4 4 4 6 6
Media capacity in cartridges
(10 cartridges per magazine) 10 10 20 20 40 80 60 120
Additional fixed cartridge
locations 2 44
2 2 4 3 6
Barcode Reader Opt. Opt. Opt. Opt. Std. Std. Std. Std.
I/O port for automated cartridge
insertion/removal Opt. Opt.Opt.Std. Std. Std. Std. Std.
Magazine carousel
(rotary positioning of magazines) No No Yes No Yes Yes Yes Yes
Magazine configuration
(# high x # wide) 1x1 1x1 1x2 2x1 2x2 2x4 2x3 2x6
Fibre Channel Option N/A Opt. Opt. Opt. Opt. Opt. Opt. Opt.
Q-Link Remote Library Manager Opt. Opt. Opt. Opt. Opt. Opt. Opt. Opt.
* The 4212 and 4222 models support only 3.5-inch tape drives
 One fixed slot is lost when the optional I/O port is installed
 Two fixed slots are lost when the optional I/O port is installed
501380 Rev. B Description and Theory of Operation 2-1

Figure 2-2 TLS-4000 Specifications
TLS-40000
Series Identifier
Maximum Number of Drives
Maximum Number of Cartridges in Magazines
Figure 2-3 Model Number Identification
MODEL HEIGHT
(in./cm)
WIDTH
(in./cm)
DEPTH
(in./cm)
NET
WEIGHT
(lb./kg)
SHIPPING 
WEIGHT
(lb./kg)
4210, 4212, 4212i 22.7 / 57.7 13.0 / 33.0 21.3 / 54.1 60 / 27.2 85 / 38.5
4222, 4222i 22.7 / 57.7 13.0 / 33.0 21.3 / 54.1 63 / 28.6 97 / 44.0
4420 37.2 / 94.5 13.7 / 34.822.2 / 56.4 85 / 38.6 110 / 49.9
4440 37.2 / 94.5 13.7 / 34.822.2 / 56.4 89 / 40.4 127 / 57.6
4480 37.2 / 94.5 13.7 / 34.822.2 / 56.4 89 / 40.4 127 / 57.6
4660, 46120 41.6 / 105.7 15.2 / 38.625.2 / 64.0 104 / 47.2 146 / 66.2
Stabilizer feet add 5.7 inches to the width.
Shipping Weights include the TLS, data cartridge magazines and accessories.
Figure 2-4 TLS-4000 Dimensions
2.2 General Description
Each TLS-4000 cabinet contains a high-performance robotics system for handling data
cartridges, a drive bay to accommodate the cartridge tape drives, at least one car-
tridge magazine, power supplies and printed circuit board assemblies (PCBAs) that
contain the TLS electronics. All models operate on any internationally available AC
power source. The TLS power cable and a single SCSI interface cable are the only re-
quired connections. The entire cabinet is pressurized and cooled by filtered air to en-
sure an optimum operating environment.
2.2.1 Motion Systems
TLS-4000 libraries contain up to four independent motion systems.
• The Carriage moves up and down vertically along the Vertical (Y) Axis.
The Carriage is driven by a brushless DC motor, which turns a nut around
a fixed, precision leadscrew.
• The Handler assembly extends and retracts along the insertion (Z) Axis
and is driven by a brushless DC motor that turn a precision leadscrew.
2-2 Description and Theory of Operation 501380 Rev. B

• The I/O port slot extends to receive or deliver a cartridge and then re-
tracts. The I/O port slot's leadscrew is driven by a DC stepper motor.
• A large gear at the bottom of the Carousel Assembly is turned by a pinion
gear on a DC stepper motor.
The drive circuitry for all motion systems is located on the Executive Printed Circuit
Board Assembly (PCBA). Each of the brushless DC motors has three internal Hall-
Effect sensors. The Hall-Effect sensors are used to commutate the motors and deter-
mine their relative positions. The brushless DC motors are driven by a three-phase
MOSFET bridge, using a 12 volt supply. Each stepper motor is driven by four discrete
MOSFET devices from the regulated 12 volt supply.
Each motion system has an opto-switch (infrared, opto-interrupter-type detector),
which is used to determine the reference position of the corresponding motion system.
2.2.2 Sensors
TLS models have two types of infrared optical sensors: analog and digital. Each opti-
cal sensor has two parts: an emitter and a corresponding detector.
Analog Sensor Operation
Analog sensors are used over longer distances than the digital sensors, which have a
range of about only one inch.
All analog infrared optical sensors produce a DC voltage proportional to the strength
of the infrared signal at the sensor. This signal is measured by the Analog to Digital
(A/D) Converter on the Executive PCBAs.
Analog Sensors
• I/O Port Clear Sensor
This sensor detects the presence of a tape cartridge in the I/O port slot.
• Y-Clear Sensor
This sensor is referred to in the Installation and Operation manual as the
Inventory Sentry Beam. A sensor consists of an infrared emitter mounted
on the bottom pan and a detector mounted on the I/O port PCBA. The in-
frared beam is modulated at a high frequency. The sensor circuitry is AC–
coupled to eliminate its sensitivity to ambient light. The Y–Clear sensor
serves three purposes:
1. When the front door is closed, the Y–Clear sensor verifies that the vertical path
traveled by the handler is unobstructed and that, therefore, it is safe for the car-
riage to move vertically.
2. When the front door is open, the Y–Clear sensor determines whether or not the
inventory has been violated, by someone reaching inside the cabinet and removing
or inserting a cartridge. Just the presence of someone's hand between the Y–Clear
sensor’s emitter and detector is sufficient to interrupt the sensor’s infrared beam
and trigger an audible alarm.
501380 Rev. B Description and Theory of Operation 2-3

3. When inserting and removing cartridges, the Y–Clear sensor is used in conjunc-
tion with the Cartridge Presence sensor to check the position of a cartridge in the
Handler's Gripper assembly.
• Cartridge Presence Sensor
This sensor, which is mounted on the handler, detects the presence of a
tape cartridge in any storage location, including a tape drive (cartridge
must be in ejected position). It utilizes the same modulated circuit as the
Y–Clear sensor. The Cartridge Presence sensor also works in conjunction
with the Y–Clear sensor to determine the position of a cartridge in the
Handler's Gripper assembly.
Digital Sensor Operation
The processor on the Executive PCBA reads the digital levels produced by the digital
sensors’ detectors.
The carousel axis has a position sensor, which looks at a pattern encoded on the gear
guard. The other three axes of motion (I/O port, vertical and insertion) have home po-
sition sensors. These sensors are used for reference purposes during initialization and
operation.
Digital Sensors
• Door Sensor
This sensor detects the condition of the cabinet door: open or closed.
When a door-open condition is detected, the system stops all moving as-
semblies.
• Carousel Position Sensor
The pattern output to this sensor by the carousel is used to determine the
position of the carousel.
• Vertical Axis Home Sensor
This sensor uses the tall pin mounted in the bottom of the cabinet to de-
tect when the Carriage Assembly reaches its home position at the bottom
of the cabinet.
• Insertion Axis Home Sensor
This sensor detects when the Carriage’s Handler Assembly (on the inser-
tion axis) is in its home position: fully retracted.
• I/O Port Full Sensor
This sensor detects when a tape cartridge is fully inserted into the I/O port
slot. It consists of an infrared emitter on a small PCBA in the I/O port as-
sembly and a sensor on the I/O port PCBA.
• I/O Port Home Sensor
This sensor detects when the I/O port slot is in its home position: fully re-
tracted.
• I/O Port Clear Sensor
This sensor detects the presence of a tape cartridge in the I/O port slot.
2-4 Description and Theory of Operation 501380 Rev. B

2.2.3 Handler Solenoid
A solenoid-operated Gripper Assembly is mounted on the Handler for grasping and re-
leasing cartridges. When current is applied to the solenoid's windings, the solenoid's
plunger extends, opening the Gripper. When the current is removed, a spring closes
the Gripper. The solenoid plunger's tip is covered with a wear-resistant nosepiece to
provide extended life.
2.2.4 Barcode Reader
A barcode reader is standard on models 4440, 4480, 4660 and 46120, and optional on
models 4210, 4212, 4222 and 4420. It is intended for use in systems where eachcar-
tridge is identified by a barcode label. Preprinted barcode labels, whichare both hu-
man-and machine-readable, are available from a number of sources.
The barcode reader consistsof a charge-coupled sensor (similar to those used in video
cameras) and associated electronics. It is mounted under the carriage. The barcode
reader can scanall cartridges in the TLS (except those loaded inside tape drives), as
well ascartridges introduced into the I/O port. Cartridges in some upper slots,includ-
ing the I/O port, must eachbe moved to a temporarylocation before their barcode la-
bels canbe read.
NOTE
The changer automaticallymoves a cartridge in the I/O port slot, or an upper Fixed slot, to a
temporary location where its barcode label can be scanned. The TLS then returns the cartridge
to its original location.
2.2.5 Barcode Labels
Pre-printed barcode labels, whichare both human- and machine-readable, are avail-
able from a number of sources includingQualstar.
Barcode labels must conform to ANSI/AIM BCI-1995, Uniform SymbologySpecifica-
tion Code 39. Please refer to PIN-040 at www.qualstar.com (click on Support tab) for
more information.
By default, the TLS expects a modulus 43 check character at the end of each label.
The use of a check character helps assure that labels are read error-free. The TLS con-
figuration must be changed before using barcode labels without a check character. All
of the labels within the TLS must match the check character configuration: either all
with or all without a check character.
2.3 Barcode Labels Usage
If the library contains a barcode reader (and barcode labels are affixed to the car-
tridges), when barcode information is read, it is stored as part of the inventory data-
base in the library's non-volatile RAM, and is available to the host computer upon re-
501380 Rev. B Description and Theory of Operation 2-5

quest. When the changer moves a cartridge, the inventory database is updated to re-
flect the change.
If the changers’ inventory becomes invalid (e.g. if the Inventory Sentry Beam is vio-
lated), the changer rescans the inventory. The updated barcode label and cartridge
position data is then stored in the inventory database. Example: After an alert that
invalidates the inventory (e.g., when a cartridge is moved by hand) is cleared, the
changer rescans the inventory. Any existing barcode labels are read and the new in-
ventory data is stored in the inventory database.
By default, the library expects a modulus 43 check character. The user must change
the changers’ configuration option before using barcode labels without a check charac-
ter. All of the labels within the TLS must be of the same check character definition:
either all with or all without.
The following steps will allow the changers’ configuration option to be set to not ex-
pect a check character.
1. Press the MENU key to display the Top Menu.
2. Press the ENTER key once to enter the \Configuration menu.
3. Press the ENTER key once to enter the \Configuration\Advanced menu.
4. Press the ENTER key once to enter the
\Configuration\Advanced\Changer menu.
5. Use the (DOWN) key to move the pointer to LabelCheckChar.
6. Press the ENTER key once to begin editing the LabelCheckChar value.
7. Press the (UP) or (DOWN) key to change the LabelCheckChar value
from YES to NO.
8. Press the MENU key to return to the Top Menu.
2.4 Component Identification
Most of the major components are common to all models. The number of tape drives
varies between models (from one to six), depending upon the size of the TLS and the
number of drives installed.
Optional, model-dependent features:
• Barcode Reader
• I/O Port
• Carousel
The theory of operation is basically the same for all models, regardless of which hard-
ware configuration is used.
2-6 Description and Theory of Operation 501380 Rev. B

2.4.1 TLS Models
Figure 2-5 and Figure 2-6 show the location of the major components in both types of
libraries: carousel and fixed-magazine models.
I/O Port Assy. Y-Clear Detectors
Control Panel
Vertical (Y) Axis
Lead Scre
w
Front Guide Shaft
Cartridge Magazine
Carriage, Handler, Grippe
r
and Barcode Reade
r
Tape Drives
Vertical (Y) Axis
Home Sensor Probe
Y-Clear Emitter Assy.
Spring Cup Assy. and Plastic Washe
r
Handler Power Supply
Executive PCBA
Tape Drive
Power Supply
Power Switch
Cooling Fans
SCSI Cable
Connectors
A
C Power Cord
Receptacle
Drive Bay PCBA
Rear Guide Shaft
Figure 2-5 TLS Side View – Fixed Magazine Model
501380 Rev. B Description and Theory of Operation 2-7

Spring Cup Assy. and Plastic Washer Handler Power Supply
I/O Port Assy.
Y-Clear Detectors
Rear Guide Shaft
Control Panel
Vertical (Y) Axis
Lead Scre
w
Front Guide Shaft
Carousel
Carriage, Handler, Grippe
r
and Barcode Reade
r
Tape Drives
Vertical (Y) Axis
Home Sensor Probe
Y-Clear Emitter Assy.
Carousel PCBA
Executive PCBA
Tape Drive
Power Supply
Power Switch
SCSI Cable
Connectors
A
C Power Cord
Receptacle
Drive Bay PCBA
Carousel Motor
Cooling Fans
Figure 2-6 TLS Side View – Carousel Model
2-8 Description and Theory of Operation 501380 Rev. B

2.4.2 Handler
Figure 2-7 shows the major components of the TLS-4000 cartridge Handler. All
TLS-4000 models use the same Handler.
Top View Bottom View
Insertion (Z)
Axis Moto
r
Grippe
r
Assembl
y
Cartridge
Presence
Senso
r
Barcode
Reader
Vertical(Y)
A
xis Motor
Figure 2-7 TLS-4000 Handler – Top and Bottom Views
2.4.3 I/O Port Assembly
Figure 2-8 shows the major components of the TLS I/O Port Assembly. The CALL
switch is mounted to the front panel and connects to the I/O port PCBA. All TLS-4000
models use the same type of I/O Port Assembly.
I/O Port Slot
I/O Port Door
5 PCBA
Mounting Screws
Motor Cable Plug
I/O Port Cable Plug
Call Switch
Cable Plug
I/O Port Lead Screw
I/O Port PCBA
I/O Port Axis Motor
I/O Full: I/O Clear
Sensor Emitter PCBA
Note: The LED’s Cable
Plug is located underneath
the I/O Port PCBA
Bottom View
Figure 2-8 I/O Port Assembly
501380 Rev. B Description and Theory of Operation 2-9

2.4.4 Field-Replaceable Units (FRUs)
Many of the library's major components are available separately as Field-Replaceable
Units (FRUs). These components can be removed and replaced in the field by qualified
personnel. See Chapter 7 for a complete list of FRUs, their part numbers and re-
moval/replacement instructions.
Some FRUs can be added to a unit as an expansion item. The instructions for install-
ing an expansion FRU for the first time, or for permanently removing an expansion
FRU are contained in Chapter 8.
2-10 Description and Theory of Operation 501380 Rev. B