Xyratex RS-1600-FC-FFX2 User manual

RS-1600-FC-FFX2
Installation and User Guide
Part No. 37592-03A
Issue 3.0
March 10, 2003

Notices
The information in this document is subject to change without notice.
While every effort has been made to ensure thatall information in this document isaccurate, the Authors
accept no liability for any errors that may arise.
No part of this document may be transmitted or copied in any form, or by any means, for any purpose,
without the written permission of the Authors.
Issue 3.0 March 10, 2003 Part No. 37592-03A
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RS-1600-FC-FFX2 User Guide

Contents
i
Contents
Preface ................................................................................................................................................... v
International Standards ........................................................................................................................... v
Potential for Radio Frequency Interference ............................................................................................ v
European Regulations ........................................................................................................................... vi
Safety ..................................................................................................................................................... vi
Battery Safety ....................................................................................................................................... viii
Rack System Precautions ....................................................................................................................... x
ESD Precautions .................................................................................................................................... x
Data Security ......................................................................................................................................... xi
Special Tools and Equipment ................................................................................................................ xi
Related Documentation ......................................................................................................................... xi
Revision History .................................................................................................................................... xii
1 Introduction ..................................................................................................................................... 1
1.1 The RS-1600-FC-FFX2 System .................................................................................................. 1
1.2 The Enclosure Core Product ....................................................................................................... 2
1.2.1 Enclosure Chassis .............................................................................................................. 2
1.2.2 Tower Option ...................................................................................................................... 3
1.3 The Plug-in Modules ................................................................................................................... 4
1.3.1 Power Supply/Cooling Module ........................................................................................... 4
1.3.2 Operators Panel ................................................................................................................. 6
1.3.3 Loop Resiliency Circuit Input/Output Module (FC-FFX2) ................................................... 7
1.3.4 Drive Carrier Module ........................................................................................................ 10
1.3.5 Dummy Carrier Modules .................................................................................................. 12
1.4 Visible and Audible Alarms ........................................................................................................ 12
1.5 RS-1600-FC-FFX2 Technical Specification .............................................................................. 12
1.5.1 Dimensions ....................................................................................................................... 12
1.5.2 Weight .............................................................................................................................. 12
1.5.3 AC Power (450W PSU) .................................................................................................... 13
1.5.4 -48V DC Power (450W PSU) ........................................................................................... 13
1.5.5 PSU Safety and EMC Compliance ................................................................................... 13
1.5.6 Power Cord ...................................................................................................................... 13
1.5.7 Environment ..................................................................................................................... 14
1.5.8 Interfaces .......................................................................................................................... 15
1.5.9 FC-FFX2 FC-AL LRC I/O Module Specification ............................................................... 15
1.5.10 Drive Carrier Module Specification ................................................................................... 16

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RS-1600-FC-FFX2 User Guide
1.5.11 Software Enclosure Services (SES) Support ................................................................... 16
1.5.12 RAID ................................................................................................................................ 16
2 Getting Started .............................................................................................................................. 17
2.1 Introduction ............................................................................................................................... 17
2.2 Planning Your Installation ......................................................................................................... 17
2.2.1 Enclosure Bay Numbering Convention ............................................................................ 18
2.3 Enclosure Installation Procedures ............................................................................................. 18
2.3.1 Pre-Requisites ................................................................................................................. 19
2.3.2 Rack Mounting Rail Kit .....................................................................................................19
2.3.3 Chassis Installation .......................................................................................................... 20
2.4 Power Supply/Cooling Module Installation ................................................................................ 20
2.4.1 Parts Check List ............................................................................................................... 20
2.4.2 AC PSU Procedure .......................................................................................................... 20
2.4.3 -48V DC PSU Procedure ................................................................................................. 23
2.5 FFX2 FC-AL I/O Module Configuration ..................................................................................... 27
2.5.1 FFX2 FC-AL Internal Loop Structures ............................................................................. 27
2.5.2 Drive Loop Structure ........................................................................................................ 27
2.5.3 Hub Function .................................................................................................................... 27
2.5.4 Supported Configuration Tools ........................................................................................ 27
2.6 FC-FFX2 FC-AL Interface ......................................................................................................... 28
2.6.1 Connecting Multiple Enclosures ....................................................................................... 28
2.7 LRC I/O Module Installation ...................................................................................................... 29
2.7.1 Parts Check List ............................................................................................................... 29
2.7.2 Procedure ........................................................................................................................ 29
2.8 Drive Enclosure Device Addressing .......................................................................................... 30
2.9 Drive Carrier Configuration ...................................................................................................... 32
2.9.1 Planning and Configuring Your Installation ...................................................................... 32
2.10 Drive Carrier Installation ............................................................................................................ 32
2.10.1 Parts Check List ............................................................................................................... 32
2.10.2 Procedure ........................................................................................................................ 32
2.10.3 Dummy Carrier Modules .................................................................................................. 34
2.10.4 Engaging the Anti-tamper Locks ...................................................................................... 34
2.11 Power Cord Connection ............................................................................................................ 35
2.11.1 Parts Check List ............................................................................................................... 35
2.11.2 Procedure ........................................................................................................................ 35
2.12 Grounding Checks .................................................................................................................... 36
3 Operation ....................................................................................................................................... 37
3.1 Before You Begin ...................................................................................................................... 37
3.2 Power On .................................................................................................................................. 37
3.2.1 Power Supply/Cooling Module LEDs ............................................................................... 38
3.3 Ops Panel LEDs ........................................................................................................................ 38
3.4 Starting the Drives ..................................................................................................................... 40
3.4.1 Disk Drives LEDs ............................................................................................................. 40
3.5 Power Down .............................................................................................................................. 40
4 Troubleshooting and Problem Solving ....................................................................................... 41
4.1 Overview ................................................................................................................................... 41
4.1.1 Initial Start-up Problems ................................................................................................... 41
4.2 LEDs ......................................................................................................................................... 42

Contents
iii
4.2.1 Power Supply/Cooling Module ......................................................................................... 42
4.2.2 Ops Panel ......................................................................................................................... 42
4.3 Audible Alarm ............................................................................................................................ 43
4.3.1 Audible Alarm Mute .......................................................................................................... 43
4.4 Troubleshooting ......................................................................................................................... 44
4.4.1 System Faults ................................................................................................................... 45
4.4.2 Power Supply/Cooling Faults ........................................................................................... 45
4.4.3 Thermal Control ................................................................................................................ 46
4.4.4 Thermal Alarm .................................................................................................................. 47
4.5 Drive Carrier Module Faults ...................................................................................................... 47
4.5.1 Dummy Carrier Modules .................................................................................................. 47
4.5.2 Auto Start Failure ............................................................................................................. 48
4.6 Dealing with Hardware Faults ................................................................................................... 48
4.7 Continuous Operation During Replacement .............................................................................. 48
4.8 Replacing a Module ................................................................................................................... 49
4.8.1 Power Supply/Cooling Modules ....................................................................................... 49
4.8.2 Ops Panel ......................................................................................................................... 54
4.8.3 LRC I/O Module ................................................................................................................ 55
4.8.4 Insertion/Removal of SFP Modules .................................................................................. 57
4.8.5 Battery Replacement ........................................................................................................57
4.8.6 Drive Carrier Module ........................................................................................................ 58
4.9 Spare Parts and Ancillary Items ............................................................................................... 59
Glossary ................................................................................................................................................ 61
Index ..................................................................................................................................................... 63

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Intentionally Blank

Preface
v
Preface
What is in this guide
This user guide gives you step-by-step instructions on how to install, configure and connect the RS-1600-
FC-FFX2 storage subsystem to your host computer system, and how to use and maintain the system.
Who should use this guide
This user guide assumes that youhave a working knowledge of the Fibre Channel Arbitrated Loop
(FC-AL) environment into which you are installing the RS-1600-FC-FFX2 system. If you do not have
these skills, or are not confident with the instructions in this guide, do not proceed with the installation.
International Standards
The RS-1600-FC-FFX2 storage system complies with the requirements of the following agencies and
standards:
• CE to IEC 950/EN60950
•UL
•cUL
Potential for Radio Frequency
Interference
USA Federal Communications Commission (FCC)
Note This equipment has been tested and found to comply with the limits for a class A digitaldevice, pursuant
to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates,
uses and can radiate radio frequency energy and, if not installed and used in accordance with the
instruction 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.
Properly shielded and grounded cables and connectors must be used in order to meet FCC emission
limits. The supplier is not responsible for any radio or television interference caused by using other than
recommended cables and connectors or by unauthorized changes or modifications to this equipment.
Unauthorized changes or modifications could void the user’s authority to operate the equipment.
This device complies with Part15 of the FCC Rules. Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.

RS-1600-FC-FFX2 User Guide
vi
European Regulations
This equipment complies with European Regulations EN 55022 Class A: Limits and Methods of
Measurement of Radio Disturbance Characteristics of Information Technology Equipments and
EN50082-1: Generic Immunity.
Safety
All plug-in modules are part of the fire enclosure and must only be removed when a replacement can be
immediately added. The system must not be run without all units in place.
Permanently unplug the unit if you think that it has become damaged in any way and before you move it.
Drive Carrier Module Caution Label:
–Do not operate with modules missing
–Spin down time 30 seconds
• An RS-1600-FC-FFX2 enclosure can weigh up to 37kg (81lb). Do not try to lift it by yourself.
Chassis Warning Label: Weight Hazard
• Do not attempt to lift the enclosure by means of the extended LRC module.
LRC I/O Module Warning Label: Lifting Hazard
• Do not lift the RS-1600-FC-FFX2 by the handles on the PSU/Cooling module, they are not designed
to support the weight of the populated enclosure.

Preface
vii
• In order to comply with applicable safety, emission and thermal requirements no covers should be
removed and all bays must be fitted with plug-in modules.
LRC Module Caution Label: Do not operate with modules missing
PSU/Cooling Module Caution Label: Do not operate with modules missing
• The RS-1600-FC-FFX2 unit must only be operated from a power supply input voltage range of 100
-120VAC or 200-240 VAC.
• The plug on the power supply cord is used as the main disconnect device. Ensure that the socket
outlets are located near the equipment and are easily accessible.
• The equipment is intended to operate with two working PSUs.
• If powered by multiple AC sources, disconnect all supply power for complete isolation
PSU Warning Label: Power Hazards
• The power connection must always be disconnected prior to removal of the Power Supply module
from the enclosure.
• A safe electrical earth connection must be provided to the power cord. Check the grounding of the
enclosure before applying power.

RS-1600-FC-FFX2 User Guide
viii
• Provide a suitable power source with electrical overload protection to meet the requirements laid
down in the technical specification.
Warning Do not remove covers from the PSU. Danger of electric shock inside. Return the PSU to your
supplier for repair.
PSU Safety Label: Electrification/Electrical Hazard
Caution Caution: If this equipment isusedin a manner notspecified by the manufacturer, the protection provided
by the equipment may be impaired.
• A faulty Power Supply/Cooling module must be replaced with a fully operational module within 24
hours.
Battery Safety
Warning The battery is not user replaceable. there is a danger of explosion if the battery is incorrectly
replaced. The battery should only be replaced by trained service personnel. Please refer to
section 4.8.5, ”Battery Replacement”, on page 57.
• Dispose of used batteries in accordance with the manufacturer’s instructions and National
regulations.

Preface
ix
-48V DC PSU/Cooling Module Safety Requirements
The following paragraphs summarize additional safety requirements to be observed when installing or
operating a -48V DC Power Supply/Cooling module: Please refer to section 2.4.3, ”-48V DC PSU
Procedure”, on page 23 for full details of European and North American safety requirements applicable
to this module.
Voltage Rating
The marked rated voltage for the-48VDC Power Supply/Cooling module is -40V DC to -60V DC. The
equipment is intended to operate from a centralized dc supply system with a NOMINAL voltage of -48V
DC or -60V DC.The voltage from a nominal -48V DC system may vary, due to float charging or discharge
conditions, from-40V DC to -60V DC.The voltage from a nominal -60V DC system mayvary, due to float
charging or discharge conditions, from -48V DC to -72V DC.
Caution If this equipment is used in a manner not specified by the manufacturer, the protection provided by the
equipment may be impaired.
Equipment Location
The rear of this Equipment (in particular the supply terminals and wiring to the terminals on the power
supply) must only be located in a “RESTRICTED ACCESS LOCATION” where both of the following
apply (Ref.UL60950):
• access can only be gained by SERVICE PERSONNEL or by USERS who have been instructed
about the reasons for the restrictions applied to the location and about any precautions that shall be
taken; and
• access is through the use of a TOOL or lock and key, or other means of security and is controlled
by the authority responsible for the location.
Disconnect Device
The wiring installation must provide a disconnect device close to the product.
Wiring
Must be connected in accordance with the local and National wiring regulations.
Wire Temperature Rating
The supply wiring to the power supply terminal blocks must have a minimum temperature rating of 75ºC.
Circuit Protection
The building installation must provide overcurrent and short circuit protection in the non earthed supply
conductor.
-48V DC PSU: USA and Canadian Safety Requirements
Wiring Methods
Wiring method must be code compliant in the field.
Wiring methods must be in accordance with the U.S. National Electric Code, Article 300.
Earthing
This equipment is designed to permit the connection of the earthed conductor (+) of the dc supply circuit
to the earthing conductor at the equipment.

RS-1600-FC-FFX2 User Guide
x
Protective Earth Conductor Size
The protective earth conductor size must be suitable for the maximum fault current that the installation
can provide. U.S. National Electric Code, Article 250-122
Branch Circuit Protection
The PSU must be connected to a Branch circuit that is protected by a LISTED Branch Protector. The
rating of the LISTED Branch Protector >= 125% of the product rating and the rating of the LISTED Branch
Protector =< current rating of wire supplying the equipment. U.S. National Electric Code, Article 210-3,
Article 240.
Rack System Precautions
The following safety requirements must be considered when the unit is mounted in a rack.
• The rack design should incorporate stabilizing features suitable to prevent the rack from tipping or
being pushed over during installation or in normal use.
• When loading a rack with the units, fill the rack from the bottom up and empty from the top down.
• The rack should comply with the airflow requirements detailed in this user guide.
• The rack design should take into consideration the maximum operating ambient temperature for the
unit, which is 40°C when dual cooling modules are fitted.
• The rack should have a safe electrical distribution system. it must provide overcurrent protection for
the unit and must not be overloaded by the total number ofunits installed in therack. Consideration
of the units nameplate rating should be used when addressing these concerns.
• The electrical distribution system must provide a reliable earth for each unit and the rack.
• Each power supply in each unit has an earth leakage current of 1.7mA. The design of the electrical
distribution system must take into consideration the total earth leakage current from all the power
supplies in all the units. The rack will require labelling with "HIGH LEAKAGE CURRENT. Earth
connection essential before connecting supply".
• The rack when configured with the units must meet the safety requirements of UL60950 and IEC
60950.
ESD Precautions
Caution It is recommended that you fit and check a suitable anti-static wrist or ankle strap and observe all
conventional ESD precautions when handling RS-1600-FC-FFX2 plug-in modules and components.
Avoid contact with backplane components and module connectors, etc.

Preface
xi
Data Security
• Power down your host computer and all attached peripheral devices before beginning installation.
• Each enclosure contains up to 16 removable disk drive modules. Disk units are fragile.Handle them
with care, and keep them away from strong magnetic fields.
•All the supplied plug-in modules and blanking plates must be in place for the air to flow correctly
around the enclosure and also to complete the internal circuitry.
• If the subsystem is used with modules or blanking plates missing for more than a few minutes, the
enclosure can overheat, causing power failure and data loss. Such use may also invalidate the
warranty.
• If you remove any drive module, you may lose data.
–If you remove a drive module, replace it immediately. If it is faulty, replace it with a drive module
of the same type and capacity
• Ensure that all disk drives are removed from the enclosure before attempting to manhandle or move
the rack installation.
• Do not abandon your backup routines. No system is completely foolproof.
Special Tools and Equipment
There are no special tools required but in order to completetheassemblyof some configurations you may
need the following (not supplied):
• Security keys (one of these should be included with your RS-1600-FC-FFX2 enclosure for use with
the drive locks).
• Cross headed screwdriver for battery removal.
Related Documentation
Mylex Encyclopedia of Controller Fundamentals & Features (P/N 775041-01, Rev C)

RS-1600-FC-FFX2 User Guide
xii
Revision History
Version Date Description of Change
1.0 January 25, 2002 Initial Release
2.0 October 29, 2002 The following illustrations revised to show new LRC I/O Module fascia:
Figures 1-3. 1-8, 1-9, 1-10, 1-11, 2-1, 2-‘4, 4-10, 4-11
Figures 2-14, 4-10 and 4-11 revised to show power cords in situ.
Preface
Safety section, pages viii to x, rewritten to include:
• Illustrations of Safety Labels used on the Enclosure system.
• The following additional safety statements:
–“Do not lift the RS-1600-FC-FFX2 by the handles on the PSU/
Cooling module, they are not designed to support the weight of
the populated enclosure.”
–“The equipment is intended to operate with two working PSUs.”
• Warning added:
Warning Do not remove covers from the PSU. Dangerof
electric shock inside. Return the PSU to your
supplier for repair.
Battery Safety, page x: section rewritten, Warning inserted, as follows:
Warning The battery is not user replaceable. there is a
danger of explosion if the battery is incorrectly
replaced. The battery should only be replaced
by trained service personnel. Please refer to
section 4.8.5, ”Battery Replacement”, on
page 57.
• Dispose of used batteries in accordance with the manufacturer’s
instructions and National regulations.
Rack System Precautions, page x: bullet point 10: “The battery is not
user replaceable and should only bedisconnected by the manufacturer.”
Deleted
Special Tools and Equipment, page xi:
• “Cross headed screwdriver for battery removal”. Inserted
Chapter 1
Figure 1-4 revised to show current Tower design.
Section 1.3.2.1, note added:
Important “The FFX2 enclosure ID must always be set to
select ID1.”
Table 1-1, switch number 3, column 3 changed from “Off” to “On”

Preface
xiii
2.0 October 29, 2002 Sections 1.5.3 and 1,54 revised:
• AC and DC PSU specs amended
New Section 1.5.5 inserted:
• PSU Safety and EMC Compliance, additional information Inserted.
Section 1.5.10 revised:
• Drive power dissipation was 22 Watts maximum, is 18.7 Watts
maximum.
Section 1.5.11: “MBTF” corrected to “MTBF”
Chapter 2
Section 2.4, new para and warning inserted:
• “Install in the rear of the enclosure in positions 1 and 5.”
Warning Do not remove covers from the power supply
unit. Danger of electric shock inside. Return
the PSU to your supplier for repair.
Section 2.4.1, Warning added:
Warning Do not mix PSU/Cooling modules of different
types.
Section 2.4.2, note added:
Important PSU2 (RH rear bay) must be fitted “upside-
down” as shown in Figure 2–1.
Sections 2.5, 2.5.1 and 2.6: para titles: FC-FFX2-FCAL changed to
FFX2-FCAL
Section 2.5.4: XDAM version revised from 1.2.7 to 1.3.4
Figure 2-11 “Hardware Configuration” revised.
Figure 2-12 “Twin Host Redundant LRC Expansion Configuration”
replaced with new illustration.
Table 2-2:
• Switch 1 settings for RAID 0 and RAID 1 changed from “N/A” to “0”
and “1” respectively.
• Note added:
Important There must be a drive present in Bay 1/1 or 4/4
to enable SES Communications to operate.
Installing drives in both of these bays will
provide redundant SES communication paths.
Chapter 3
Table 3-2 amended:
• “12C” changed to “I2C” in column 8, row 8.
Version Date Description of Change

RS-1600-FC-FFX2 User Guide
xiv
2.0 October 29, 2002 Chapter 4
Table 4-2 amended:
• “12C” changed to “I2C” in column 8, row 8.
Section 4.8.1, Warning added:
Warning Do not remove covers from the power supply
unit. Danger of electric shock inside. Return
the PSU to your supplier for repair.
Section 4.8.3.1, note added and step 1 revised as follows:
Note As there should always be two LRC I/O modules
installed, you can continue working while replacing
the faulty module.
1Ensure that you correctly identify the faulty module
from the two modules installed.
Section 4.8.4: step 1 deleted.
Section 4.8.5 renumbered to 4.8.6 and new section 4.8.5 inserted,
“Battery Replacement”.
Section 4.9: Battery added to spare parts list.
Glossary
Definitions of “Module” and “ESI/Ops panel” revised to reflect the fact
that the ESI/Ops panel is an integral part of the Enclosure and not a
removable module.
3.0 February 24, 2003 Preface
Safety
Additional bullet point added:
• A faulty Power Supply/Cooling module mustbe replaced with a fully
operational module within 24 hours.
Rack Safety:
Bullet points 1 & 3 replaced by new bullet 1:
• The rack design should incorporate stabilizing features suitable to
prevent the rack from tipping or being pushed over during
installation or in normal use.
New bullet 3:
technical specification changed to user guide.
Bullet point 8:
UL 1950 changed to UL 60950.
Version Date Description of Change

Preface
xv
3.0 February 24, 2003 Chapter 1
Table 1-1:
Switch 3: “RAID Host FC ports will not be linked together internally”
changed to: “RAID Host FC ports will be linked together internally”
Version Date Description of Change

RS-1600-FC-FFX2 User Guide
xvi
Intentionally Blank

Introduction
1
Chapter 1
Introduction
1.1 The RS-1600-FC-FFX2 System
.
Figure 1–1 The RS-1600-FC-FFX2 (FC-AL) System

RS-1600-FC-FFX2 User Guide
2
1.2 The Enclosure Core Product
The RS-1600-FC-FFX2 design concept is based on a subsystem together with a set of plug-in modules.
The RS-1600-FC-FFX2 subsystem as supplied comprises:
• Chassis and Backplane with integral Operators Panel.
• 2 Power Supply/Cooling plug-in modules two variants are available:
–.AC, 450W PSU.(see Figure 1–5)
–-48V DC, 450W PSU (see Figure 1–6)
• FC-AL Drive Carrier Modules and associated dummy carrier modules (See Figure 1–12).
• FC-AL LRC 2Gb/s Input/Output Modules with integrated Mylex San Array ProFFX2 RAID
controllers.(See Figure 1–9).
1.2.1 Enclosure Chassis
The chassis consists of a sheet metal enclosure assembly containing a Backplane PCB and module
runner system. This chassis assembly also includes an integral Ops Panel, mounted at the rear.
The chassis assembly contains 16 drive bays at the front, each of which accommodates a plug-in drive
carrier module. The 16 drive bays are arranged in 4 rows of 4 drives. At the rear, the chassis assembly
contains 5 module bays to house Power Supply/Cooling modules and LRC I/O modules
The Backplane PCBprovides logiclevelsignaland low voltage power distribution paths. Figure 1–2 and
Figure 1–3 show front and rear views of an RS-1600 chassis respectively.
The 4 x 4 chassis is fitted with 19 inch Rack mounting features which enables it to be fitted to standard
19 inch racks and uses 3EIA units of rack space.
• A Bay is defined as the space required to house a single 1.0" high 3.5 inch disk drive in its carrier
module. e.g. a 1 x 4 bay module would take the space of 1 drive width by 4 drive bays high (in rack
mount configuration).
.
Figure 1–2 Enclosure Chassis (Front)