Overland Storage NEO 8000 Replacement Instruction

Brand: Overland Storage

Model: NEO 8000

Category: Fitness, gymnastics & weight training

Type: Replacement Instruction

Part Number 104380-101

Released 09/2005

Overland NEO 8000

Remove & Replace Instructions

Z-Axis Robotics Retrofit

ii X Part Number 104380-101 09/2005

Proprietary Notice

All information contained in or disclosed by this document is considered proprietary by Overland

Storage. By accepting this material, the recipient agrees that this material and the information

contained therein are held in confidence and in trust and will not be used, reproduced in whole or in

part, nor its contents revealed to others, except to meet the purpose for which it was delivered. It is

understood that no right is conveyed to reproduce or have reproduced any item herein disclosed

without express permission from Overland Storage. Overland Storage provides this manual as is,

without warranty of any kind, either expressed or implied, including, but not limited to, the implied

warranties of merchantability and fitness for a particular purpose. Overland Storage may make

improvements or changes in the products or programs described in this manual at any time. These

changes will be incorporated in new editions of this publication.

Overland Storage assumes no responsibility for the accuracy, completeness, sufficiency, or

usefulness of this manual, nor for any problem that might arise from the use of the information in

this manual.

Overland products are covered by one or more of the following patents registered with the USPTO:

5,870,245; 6,328,766; 6,353,581; 6,496,325.

Worldwide Headquarters Overland Storage, Inc.

4820 Overland Avenue

San Diego, CA 92123

Toll Free: (800) 729-8725

Tel: (858) 571-5555

Fax: (858) 571-3664

Sales Tel: (858) 571-5555

Fax: (858) 571-3664

E-mail: sales@overlandstorage.com

www.overlandstorage.com

Technical Support Tel: (858) 571-5555

Fax: (858) 571-3664

Toll Free: (877) 654-3429

E-mail: techsupport@overlandstorage.com

Overland Storage, EMEA Overland House, Ashville Way

Wokingham, Berkshire

RG41 2PL, England

Tel: +44 (0) 118-9898000

Fax: +44 (0) 118-9891897

www.overlandstorage.com

Part Number 104380-101 09/2005 W iii

Preface

About this Guide

This Remove & Replace guide provides instructions and information required for the

removal and replacement of the Overland Storage Z-Axis Belt Drive Assemblies (BDA) in

a NEO 8000™ Library that have been identified as possibly having an incorrect pulley

installed.

NOTE: This applies only to certain libraries built between December 2004 and May 2005.

Conventions

This user guide exercises several typographical conventions.

Convention Description & Usage

Boldface Words in boldface indicate items to select such as menu items or

command buttons.

Ctrl-Alt-r This type of format details the keys you press simultaneously. In this

example, hold down the Ctrl and Alt keys and press the r key.

NOTE A Note indicates neutral or positive information that emphasizes or

supplements important points of the main text. A note supplies

information that may apply only in special cases—for example, memory

limitations or details that apply to specific versions of a program.

IMPORTANT An Important note is a type of note that provides information essential

to the completion of a task or that can impact the product and its

function. Users can disregard information in a regular note and still

complete a task, but they should not disregard an important note.

CAUTION A Caution contains information that the user needs to know to avoid

damaging or permanently deleting data or causing physical damage to

the hardware or system.

WARNING A Warning contains information essential to people’s safety. It

advises users that failure to take or avoid a specific action

could result in physical harm to the user or hardware.

iv X Part Number 104380-101 09/2005

Preface

Overland Storage Technical Support

For more assistance, search for help at:

http://support.overlandstorage.com/

Our Overland Storage Technical Support staff is also available to assist you by phone at:

1.877.654.3429 (Toll-free and active only in US and Canada)

1.858.571.5555 x5 (Worldwide)

On normal business days 6 AM through 5 PM (California time) excluding Overland holidays.

At all other times we will respond to technical support calls within 4 hours.

Technical support for our European customers is available as well from our United Kingdom

office at:

+44 (0) 118-9898050

9:00 am to 5:00 pm (GMT)

Monday through Friday

You can e-mail our technical support staff at [email protected].

Part Number 104380-101 09/2005 W v

Table of Contents

Preface

About this Guide ..................................................................................................................... iii

Conventions ............................................................................................................................. iii

Overland Storage Technical Support ...................................................................................iv

Chapter 1 - Introduction

Replacement Process Overview ........................................................................................ 1-1

Required Tools .................................................................................................................1-2

Electrostatic Discharge Information ................................................................................... 1-2

Unpacking the Retrofit Kit .................................................................................................... 1-2

Chapter 2 - Prepare the Library for Internal Access

Removal of Media Drawers ................................................................................................ 2-1

Power Down the Library ...................................................................................................... 2-2

Remove Panels for Access .................................................................................................. 2-2

Front Panel Assembly ..................................................................................................... 2-2

Rear Access Panels ........................................................................................................ 2-4

Chapter 3 - Replace the Front BDA

Remove the Front BDA ........................................................................................................ 3-1

Move the Drive Motor .......................................................................................................... 3-2

Reinstall the Front BDA ......................................................................................................... 3-3

Chapter 4 - Replace the Rear BDA

Remove the Rear BDA ......................................................................................................... 4-1

Move the Drive Motor .......................................................................................................... 4-2

Reinstall the Rear BDA .........................................................................................................4-4

Chapter 5 - Verify the Robotics Level and Height

Verify the Monorail is Level .................................................................................................. 5-1

Verify the Picker Height .......................................................................................................5-3

Chapter 6 - Verify the Library Operation

Reattach the Library Panels and Components ................................................................ 6-1

Rear Access Panels ........................................................................................................ 6-1

Front Panel Assembly ..................................................................................................... 6-1

Media Drawers ................................................................................................................ 6-1

Power on the Library System ............................................................................................... 6-2

Test the Library ...................................................................................................................... 6-2

Appendix A - Moving the Library

Move the Library Out for Access ........................................................................................A-1

Move the Library Back in Place ..........................................................................................A-2

Part Number 104380-101 09/2005 W vi

List of Figures

Chapter 1 - Introduction

Chapter 2 - Prepare the Library for Internal Access

Figure 2-1: Access Plates and Components That Need To Be Removed ...................... 2-1

Figure 2-2: Left Bottom Rack Cover Trim Piece.................................................................. 2-2

Figure 2-3: Front Panel Assembly Screw Locations............................................................ 2-3

Figure 2-4: Location of the J3 GUI PWA Connector .......................................................... 2-3

Chapter 3 - Replace the Front BDA

Figure 3-1: Locations of the J2 and J4 Drive PWA Connectors........................................ 3-1

Figure 3-2: Location of the 1/8” Hex Shoulder Screw........................................................ 3-2

Figure 3-3: Location of the Helical Coupling Front Cap Screw ....................................... 3-2

Figure 3-4: Location of the Three Drive Motor Pan Head Screws .................................... 3-3

Chapter 4 - Replace the Rear BDA

Figure 4-1: Base of Rear BDA and Connected Components .......................................... 4-1

Figure 4-2: Location of the Rotary SPI PWA Connectors................................................... 4-2

Figure 4-3: Location of the Helical Coupling Front Cap Screw ....................................... 4-3

Figure 4-4: Location of the Three Drive Motor Pan Head Screws .................................... 4-3

Chapter 5 - Verify the Robotics Level and Height

Figure 5-1: Removing Shims from the BDA.......................................................................... 5-1

Figure 5-2: Taking a Measurement with the Calipers........................................................ 5-2

Figure 5-3: Picker Height Tool in Position ............................................................................. 5-3

Figure 5-4: Position the Picker Against the Picker Height Tool.......................................... 5-4

Chapter 6 - Verify the Library Operation

Figure 6-1: Starting the Cartridge Cycle Test ..................................................................... 6-2

Appendix A - Moving the Library

Figure A-1: Leveler Reference Marks on Floor....................................................................A-1

Figure A-2: Positioning the Level ..........................................................................................A-2

Part Number 104380-101 09/2005 W 1–1

CHAPTER

Introduction

Each Z-Axis Belt Drive Assembly (BDA) consists of a pole with belts and pulleys that

move one end of the Shuttle Assembly vertically inside the library.

IMPORTANT: Overland Storage recommends that the BDAs be replaced by an Overland

Storage authorized service provider. Improper removal and replacement may result in

damage to this part or library components which would void all existing warranties.

Replacement Process Overview

Described below are the major steps required to remove and replace the BDAs in a NEO

8000. Unless otherwise noted, all hardware is included in the BDA kit.

NOTE: Always retain any screws removed during this procedure. They will be reused to reinstall

the appropriate components.

Step 1: Prepare the Library for Internal Access

• Only if necessary, move the library system to provide working room.

• Remove both side panels for easy access to change out the BDAs.

• Optionally, remove access panels at the rear of the library.

Step 2: Replace the Front BDA

• Remove the old BDA from the library.

• Move the motor to the new BDA.

• Install the new BDA into the library.

Step 3: Replace the Rear BDA

• Disconnect the shuttle wiring from the rear BDA.

• Remove the old BDA from the library.

• Move the motor to the new BDA.

• Install the new BDA into the library.

Step 4: Verify the Robotics Level and Height

• Verify the shuttle robotics are level.

• Verify that the picker is at the proper height.

• Replace all components removed to allow access.

Step 5: Verify the Library Operation

• Power on the library.

• Check the library operation using the cartridge cycle test.

1–2 X Part Number 104380-101 09/2005

Chapter 1: Introduction

Required Tools

These tools are required for the proper removal and replacement of the BDAs:

• #1 and #2 Phillips Screwdrivers

• #2 Stubby Phillips Screwdriver

• 1/8” Hex Key

• 7/64” Hex Key

• 3mm Hex Key

• Calipers (digital calipers strongly recommended)

• 607078-750, Tool Gage, Height, Z-Axis, LXN 8000

• 607078-751, Tool Picker Height, Gage, LXN 8000

These tools are required only if you need to level the library:

• 6" or 10" Spirit Level (15cm or 25cm)

• 10" Adjustable Wrench (260mm)

Electrostatic Discharge Information

A discharge of static electricity can damage static-sensitive devices. Proper packaging and

grounding techniques are necessary precautions to prevent damage. To prevent electrostatic

damage, observe the following precautions.

• Transport products in static-safe containers such as conductive tubes, bags, or boxes.

• Keep electrostatic-sensitive parts in their containers until they arrive at static-free

stations.

• Cover the library with approved static-dissipating material.

• Use a wrist strap connected to the work surface and properly-grounded tools and

equipment.

• Keep the work area free of non-conductive materials such as foam packing materials.

• Make sure you are always properly grounded when touching a static-sensitive

component or assembly.

• Avoid touching pins, leads, or circuitry.

Unpacking the Retrofit Kit

Carefully unpack the new components noting how they are packed in the shipping carton.

When this procedure is complete, repack the old parts in the same container for shipment

back to Overland Storage.

Part Number 104380-101 09/2005 W 2–1

CHAPTER

Prepare the Library for Internal Access

To simplify the replacement of the two internal BDAs, remove the Front Panel Assembly

(FPA) and other components to provide easier access or visibility to the inside of the

library (Figure 2-1).

Figure 2-1: Access Plates and Components That Need To Be Removed

NOTE: This procedure is based on the assumption that the library is located in a row of

equipment racks that prevent access to the side panels. If the side panels can be

removed, the process will be much easier. If moving the library is practical, refer to

Appendix A, “Moving the Library.”

Removal of Media Drawers

Using Menu > Maintenance > Access All Drawers > Unlock All, release and remove

all the media drawers to provide access to both the front and rear BDAs.

WARNING: Exercise care when removing the media drawers from the library units.

Fully-loaded drawers weigh approximately 58 pounds (26.3 kg). Also, when the

drawers are removed, the rails extend several inches beyond the back of the drawers.

Use care when handling the drawers.

NOTE: Label the drawers so they can be returned to their correct positions when they are

reinserted.

Remove

the FPA

Remove This

Access Plate

Rear ViewFront View

Remove These

Media Drawers

Remove These

Media Drawers

Optionally,

Remove These

Drives/Plates

Remove This

Access Plate

2–2 X Part Number 104380-101 09/2005

Chapter 2: Prepare the Library for Internal Access

Power Down the Library

WARNING: Working with a powered NEO 8000 library may cause physical harm and

severe damage to unit’s circuitry. Always power down a library before removing any

panels.

1. Power down the library at the front panel.

2. Set the library circuit breakers to the OFF (“O”) position.

3. Remove and retain the power cords.

Remove Panels for Access

The removal of various panels from the library is necessary to access the BDAs.

CAUTION: Follow ESD protocols when working with the PWA printed circuit boards.

Front Panel Assembly

1. At the left bottom rack cover trim piece, remove and retain the screw attaching it to

the FPA (Figure 2-2).

Figure 2-2: Left Bottom Rack Cover Trim Piece

2. Push the trim piece back and up to remove it.

3. Repeat Steps 1–2 for the right bottom rack cover trim piece.

4. At the base of the FPA, remove the pan head screws on each side (Figure 2-3).

Remove

This Pan

Bottom Rack

Cover Trim

FPA

Head Screw

Part Number 104380-101 09/2005 W 2–3

Remove Panels for Access

Figure 2-3: Front Panel Assembly Screw Locations

5. Supporting the FPA, remove the flat head screws at the top on each side.

NOTE: Be sure to keep the two sets of screws separate. The FLAT head screws must be used

at the TOP of the FPA to prevent interference with the operation of the top drawers.

6. Pivot the FPA out far enough to remove the J3 connector (Figure 2-4) at the top of

the GUI PWA.

Figure 2-4: Location of the J3 GUI PWA Connector

7. Remove the cable from the retainers on the back side of FPA and set aside the FPA.

CAUTION: Lay the FPA on a safe, secure surface that won’t damage the bezel.

Remove

Flat Head

Screws

Remove

Pan Head

Screws

CON2

Unplug

2–4 X Part Number 104380-101 09/2005

Chapter 2: Prepare the Library for Internal Access

Rear Access Panels

At the rear of the library, remove and retain the top-right and the bottom-right access

panels and hardware.

For additional visibility and access, remove the drives or drive panels 1, 2, 3, 4, 11, and 12

and their associated drive dividers (Figure 2-1).

Part Number 104380-101 09/2005 W 3–1

CHAPTER

Replace the Front BDA

You are now ready to replace the old BDAs. Each new BDA comes ready to install. The

only requirement is moving the drive motor from the old assembly to the new one.

CAUTION: Follow ESD protocols when working with the Drive PWA printed circuit boards.

Remove the Front BDA

1. Remove and retain the two screws attaching the front Drive PWA cover.

2. Unplug the J2 and J4 connectors from the Drive PWA (Figure 3-1).

Figure 3-1: Locations of the J2 and J4 Drive PWA Connectors

NOTE: You can temporarily reattach the cover to protect the Drive PWA during extraction.

Unplug

3–2 X Part Number 104380-101 09/2005

Chapter 3: Replace the Front BDA

3. Using the 1/8” hex key, remove and retain the shoulder screw and washers

(Figure 3-2) that attach the monorail bracket to the BDA.

Figure 3-2: Location of the 1/8” Hex Shoulder Screw

4. Remove and retain the bottom screws holding the BDA to the mounting bracket.

5. Supporting the BDA, remove and retain the top screws from the mounting bracket.

6. Moving the top of the BDA to the left and the bottom slightly to the right (to clear the

mounting brackets), remove the assembly from the library.

Move the Drive Motor

1. With the BDA positioned securely, use a 7/64” hex key to loosen the front cap screw

on the drive’s helical coupling (Figure 3-3).

Figure 3-3: Location of the Helical Coupling Front Cap Screw

Shoulder

Monorail

Bracket

Z-Axis BDA

Screw

BDA Mounting

Bottom

Mounting

Bracket

Screws

Hex

Front Helical

Coupling Cap

Screw

Part Number 104380-101 09/2005 W 3–3

Reinstall the Front BDA

2. Using a 3mm hex key, remove and retain the three cap screws holding the motor to

the BDA (Figure 3-4).

Figure 3-4: Location of the Three Drive Motor Pan Head Screws

3. Slide the motor off the old BDA’s drive shaft

4. Slide the motor onto the new BDA’s drive shaft.

5. Using a 3mm hex key, attach the motor to the new BDA using three retained cap

screws.

6. Using a 7/64” hex key, tighten the front cap screw on the drive’s helical coupling.

Reinstall the Front BDA

NOTE: You can temporarily reattach the cover to protect the Drive PWA during insertion.

1. Holding the top of the BDA to the left and the bottom slightly to the right, insert the

assembly into the library.

2. Supporting the BDA, use the two retained screws to reattach it to the top mounting

bracket.

3. Use the two retained screws to reattach the BDA to the bottom mounting bracket.

4. Using the 1/8” hex key, use the retained shoulder screw and washers (Figure 3-2) to

reattach the monorail bracket to the BDA.

NOTE: Be sure there are two washers used with the monorail bracket shoulder screw. Add a

second washer if necessary.

5. On the Drive PWA, reattach the J2 and J4 connectors.

6. Use the two retained screws to reattach the Drive PWA cover.

Remove These

Three Screws

Drive Motor

Motor PWA

3–4 X Part Number 104380-101 09/2005

Chapter 3: Replace the Front BDA

Part Number 104380-101 09/2005 W 4–1

CHAPTER

Replace the Rear BDA

CAUTION: Follow ESD protocols when working with the PWA printed circuit boards.

Remove the Rear BDA

The Rotary SPI PWA and Shuttle Support need to also be removed from the rear BDA

before it can be replaced (Figure 4-1).

Figure 4-1: Base of Rear BDA and Connected Components

1. At the rear drive motor, remove and retain the two screws attaching the rear

Drive PWA cover.

2. Unplug the J2 and J4 connectors from the Drive PWA.

NOTE: You can temporarily reattach the cover to protect the Drive PWA during extraction.

Z-Axis BDA

Cable Clip

Drive Motor

Belt

Rotary Motor

Shuttle

Support Bracket

and Optical

Sensor Cables

Rotary

SPI PWA

Bottom

Mounting

Bracket

Cable Ties

Mounting

Bracket

D-Clamp

Bracket

Screws

4–2 X Part Number 104380-101 09/2005

Chapter 4: Replace the Rear BDA

3. On the Rotary SPI PWA, unplug the J3, J4, J6, and J7 connectors (Figure 4-2).

Figure 4-2: Location of the Rotary SPI PWA Connectors

4. Remove and retain the cable clip and cut the two cable ties holding the Shuttle

Signal cable to the Rotary SPI PWA mounting bracket.

5. From the front, remove and retain the two screws holding the Shuttle support

bracket to the Belt mounting bracket.

Lay the bracket and cables down on the bottom of the library.

6. From the rear, remove and retain the two screws holding the Rotary SPI PWA

mounting bracket to the Belt mounting bracket.

Lay the bracket and cables down on the bottom of the library.

7. Carefully remove the Rotary Motor and Optical Sensor cables from under the Belt

mounting bracket and move them to the front removing them from the D-clamp.

8. Using the 1/8” hex key, remove and retain the shoulder screw and washers

(Figure 4-1) that attach the monorail bracket to the BDA.

9. Remove and retain the bottom screws holding the BDA to the mounting bracket.

10. Supporting the BDA, remove and retain the top screws from the mounting bracket.

11. Tilting the BDA to clear all the internal components, remove the assembly from the

library.

Move the Drive Motor

1. With the BDA positioned securely, use a 7/64” hex key to loosen the front cap screw

on the drive’s helical coupling (Figure 4-3).

Unplug

Part Number 104380-101 09/2005 W 4–3

Move the Drive Motor

Figure 4-3: Location of the Helical Coupling Front Cap Screw

2. Using a 3mm hex key, remove and retain the three cap screws holding the motor to

the BDA (Figure 4-4).

Figure 4-4: Location of the Three Drive Motor Pan Head Screws

3. Slide the motor off the old BDA’s drive shaft

4. Slide the motor onto the new BDA’s drive shaft.

5. Using a 3mm hex key, attach the motor to the new BDA using three retained cap

screws.

6. Using a 7/64” hex key, tighten the front cap screw on the drive’s helical coupling.

Front Helical

Coupling Cap

Screw

Remove These

Three Screws

Drive Motor

Motor PWA

4–4 X Part Number 104380-101 09/2005

Chapter 4: Replace the Rear BDA

Reinstall the Rear BDA

NOTE: You can temporarily reattach the cover to protect the Drive PWA during insertion.

1. Tilting the BDA to clear all the internal components, insert the assembly into the

library.

2. Supporting the BDA, use the two retained screws to reattach it to the top mounting

bracket.

3. Use the two retained screws to reattach the BDA to the bottom mounting bracket.

4. Using the 1/8” hex key, use the retained shoulder screw and washers (Figure 4-1)

to reattach the monorail bracket to the BDA.

NOTE: Be sure there are two washers used with the monorail bracket shoulder screw. Add a

second washer if necessary.

5. Carefully route the Rotary Motor and Optical Sensor cables under the Belt

mounting bracket and to the rear, reattaching them in the D-clamp.

6. From the rear, use the two retained screws to reattach the Rotary SPI PWA

mounting bracket to the Belt mounting bracket.

7. From the front, use the two retained screws to reattach the Shuttle support bracket

to the Belt mounting bracket.

8. Reposition the Shuttle Signal cable on the Rotary SPI PWA mounting bracket and

reattach it using the cable clip.

9. Loop a new cable tie around the Shuttle Signal cable on the Rotary SPI PWA

mounting bracket to secure the cable.

10. Loop a new cable tie around the Shuttle Signal cable and the pulley cable where it

attaches to the Belt mounting bracket to secure it.

11. On the Rotary SPI PWA, reattach the J3, J4, J6, and J7 connectors.

12. On the Drive PWA, reattach the J2 and J4 connectors.

13. Use the two retained screws to reattach the Drive PWA cover.

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Overland Storage NEO 8000 Replacement Instruction

Brand: Overland Storage

Model: NEO 8000

Category: Fitness, gymnastics & weight training

Type: Replacement Instruction

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Overland Storage NEO 8000 Replacement Instruction

Overland Storage NEO 8000 Replacement Instruction

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