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ProLiant 6400R
Maintenance and Service Guide
Third Edition (April 2000)
Part Number 401054-003
Spare Part Number 101978-003
Compaq Computer Corporation
Notice
The information in this publication is subject to change without notice.
COMPAQ COMPUTER CORPORATION SHALL NOT BE LIABLE FOR TECHNICAL OR
EDITORIAL ERRORS OR OMISSIONS CONTAINED HEREIN, NOR FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING, PERFORMANCE, OR USE
OF THIS MATERIAL. THIS INFORMATION IS PROVIDED “AS IS” AND COMPAQ COMPUTER
CORPORATION DISCLAIMS ANY WARRANTIES, EXPRESS, IMPLIED OR STATUTORY AND
EXPRESSLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR
PARTICULAR PURPOSE, GOOD TITLE AND AGAINST INFRINGEMENT.
This publication contains information protected by copyright. No part of this publication may be
photocopied or reproduced in any form without prior written consent from Compaq Computer Corporation.
© 2000 Compaq Computer Corporation.
All rights reserved. Printed in the U.S.A.
The software described in this guide is furnished under a license agreement or nondisclosure agreement.
The software may be used or copied only in accordance with the terms of the agreement.
Compaq, Deskpro, Fastart, Compaq Insight Manager, Systempro, Systempro/LT, ProLiant, ROMPaq,
QVision, SmartStart, NetFlex, QuickFind, PaqFax, ProSignia, registered United States Patent and
Trademark Office.
Neoserver, Netelligent, Systempro/XL, SoftPaq, QuickBlank, QuickLock are trademarks and/or service
marks of Compaq Computer Corporation.
Microsoft, MS-DOS, Windows, and Windows NT are registered trademarks of Microsoft Corporation.
Pentium is a registered trademark and Xeon is a trademark of Intel Corporation.
Other product names mentioned herein may be trademarks and/or registered trademarks of their respective
companies.
Compaq ProLiant 6400R Maintenance and Service Guide
Third Edition (April 2000)
Part Number 401054-003
Spare Part Number 101978-003
Contents
About This Guide
Symbols in Text.........................................................................................................vii
Symbols on Equipment.............................................................................................viii
Compaq Technician Notes .........................................................................................ix
Where to Go for Additional Help ............................................................................... ix
Integrated Management Display........................................................................... x
Telephone Numbers ............................................................................................. x
Chapter 1
Illustrated Parts Catalog
Mechanical Parts Exploded View.............................................................................1-2
Mechanical Spare Parts List .....................................................................................1-3
System Components Exploded View .......................................................................1-4
System Components Spare Parts List.......................................................................1-5
Chapter 2
Removal and Replacement Procedures
Electrostatic Discharge Information.........................................................................2-1
Symbols on Equipment.............................................................................................2-2
Preparation Procedures.............................................................................................2-3
Hot-Pluggable Components ..............................................................................2-3
Non-Hot-Pluggable Components ......................................................................2-3
Powering Down the Server................................................................................2-3
Server Warnings and Precautions......................................................................2-4
Top Access Panel .....................................................................................................2-5
Power On/Standby Switch........................................................................................2-6
Front Bezel ...............................................................................................................2-8
Hot-Plug Fans...........................................................................................................2-9
I/O Hot-Plug Fans ...........................................................................................2-10
Hot-Plug Dual Redundant CPU Fan Assembly...............................................2-11
External Rear Hot-Plug Redundant System Fan Assembly.............................2-12
Removable Media and Hard Drives .......................................................................2-12
Media Storage .................................................................................................2-13
Hot-Plug Hard Drives......................................................................................2-14
Ultra2 SCSI Simplex Board ...................................................................................2-16
Removable Media Assembly..................................................................................2-17
1.44-MB Diskette Drive..................................................................................2-18
24X or Higher Low-Profile CD-ROM Drive Adapter Board..........................2-19
24X or Higher Low-Profile CD-ROM Drive ..................................................2-20
iv Compaq ProLiant 6400R Maintenance and Service Guide
Removal and Replacement Procedures
continued
Cable Folding and Routing Diagrams ....................................................................2-21
24X or Higher Low-Profile CD-ROM Cable ..................................................2-21
Diskette Drive Cable .......................................................................................2-22
External Fan Cable..........................................................................................2-22
Power Supply Cable ........................................................................................2-23
Power Supply Signal Cable.............................................................................2-24
Hot-Plug Power Supply..........................................................................................2-25
Processors, Processor Terminator Modules, and Processor Power Modules..........2-26
Processor and Related Component Locations .................................................2-26
Processor .........................................................................................................2-27
Processor Power Module.................................................................................2-28
Processor Terminator Module .........................................................................2-29
Peripheral Board.....................................................................................................2-30
Memory ..................................................................................................................2-31
Address Bit Permuting ....................................................................................2-32
Memory Board ................................................................................................2-33
Dual Inline Memory Modules .........................................................................2-34
PCI Hot Plug Expansion Boards ............................................................................2-35
PCI Hot Plug Basket Insulator................................................................................2-39
PCI Hot Plug Switch/LED Board and Cable..........................................................2-40
Power Backplane Board Assembly ........................................................................2-40
Side Access Panel...................................................................................................2-44
System Board and Tray ..........................................................................................2-44
AC Power Cord and Plug Assembly ......................................................................2-45
Replacement Battery ..............................................................................................2-49
Chapter 3
Diagnostics and Troubleshooting
Diagnostic Tools Utility Overview...........................................................................3-1
Default Configuration...............................................................................................3-4
Default Configuration Messages .......................................................................3-4
Inspect Utility....................................................................................................3-4
Utilities Access.........................................................................................................3-5
Running Compaq Utilities.................................................................................3-5
Power-On Self-Test..................................................................................................3-6
Error Messages of the Power-On Self-Test.......................................................3-7
Diagnostics Software..............................................................................................3-20
Steps for Diagnostics.......................................................................................3-21
100 – 199, Primary Processor Test Error Codes .............................................3-22
200 – 299, Memory Test Error Codes.............................................................3-23
300 – 399, Keyboard Test Error Codes ...........................................................3-23
400 – 499, Parallel Printer Test Error Codes...................................................3-24
500 – 599, Video Display Unit Test Error Codes............................................3-25
600 – 699, Diskette Drive Test Error Codes ...................................................3-26
1100 – 1199, Serial Test Error Codes .............................................................3-27
1200 – 1299, Modem Communications Test Error Codes ..............................3-27
1700 – 1799, Hard Drive Test Error Codes.....................................................3-28
1900 – 1999, Tape Drive Test Error Codes.....................................................3-29
6000 – 6099, Compaq NIC Boards Test Error Codes .....................................3-29
6500 – 6599, SCSI Hard Drive Test Error Codes ...........................................3-30
6600 – 6699, SCSI/IDE CD-ROM Drive Test Error Codes............................3-30
6700 – 6799, SCSI Tape Drive Test Error Codes ...........................................3-31
8600 – 8699, Pointing Device Interface Test Error Codes..............................3-31
Contents v
Diagnostics and Troubleshooting
continued
Array Diagnostic Utility.........................................................................................3-31
Starting ADU...................................................................................................3-32
Integrated Management Log...................................................................................3-43
Multiple Ways of Viewing the Log.................................................................3-43
Event List ........................................................................................................3-45
Event Messages...............................................................................................3-45
Rapid Error Recovery.............................................................................................3-47
Automatic Server Recovery-2 .........................................................................3-48
Server Health Logs..........................................................................................3-57
ASR-2 Integrated Management Log Messages ...............................................3-57
Storage Fault Recovery Tracking....................................................................3-60
Storage Automatic Reconstruction..................................................................3-60
Network Interface Fault Recovery Tracking ...................................................3-61
Memory Fault Recovery Tracking ..................................................................3-61
Remote Service Features ........................................................................................3-61
ROMPaq Error Recovery Options..........................................................................3-62
ROMPaq Disaster Recovery ...........................................................................3-62
Redundant ROM Image Recovery ..................................................................3-63
Compaq Insight Manager .......................................................................................3-64
Features ...........................................................................................................3-64
Compaq Insight Management Software Architecture .....................................3-65
Chapter 4
Connectors, Switches, and LED Indicators
Connectors................................................................................................................4-1
Rear Panel Connectors ......................................................................................4-1
System Board Connectors .................................................................................4-3
Peripheral Board Connectors.............................................................................4-4
Power Backplane Board Connectors .................................................................4-5
Ultra2 SCSI Simplex Board Connectors ...........................................................4-6
Switches ...................................................................................................................4-7
Maintenance Configuration Switchbank (SW1)................................................4-7
Processor Core Frequency Switches (SW2 and SW3) ......................................4-8
LED Indicators .........................................................................................................4-9
Hot-Plug Power Supply LED Indicators ...........................................................4-9
Hot-Plug Fan LED Indicators..........................................................................4-10
Front Bezel LED Indicators ............................................................................4-11
PCI Hot Plug Board LED Indicators ...............................................................4-13
Hot-Plug Hard Drives......................................................................................4-15
Interlock LED Indicators.................................................................................4-16
Chapter 5
Physical and Operating Specifications
System Unit ..............................................................................................................5-2
Hot-Plug Power Supply............................................................................................5-3
Dual Inline Memory Modules (DIMMs)..................................................................5-4
1.44-MB Diskette Drive ...........................................................................................5-4
24X or Higher Low-Profile CD-ROM Drive ...........................................................5-5
NC3131 Fast Ethernet NIC 64 PCI Dual Base10/100 Controller.............................5-6
Hot-Plug Hard Drives...............................................................................................5-7
Index
About This Guide
This maintenance and service guide is a troubleshooting guide that can be used for reference
when servicing Compaq ProLiant 6400R servers.
WARNING: To reduce the risk of personal injury from electrical shock and hazardous energy
levels, only authorized service technicians should attempt to repair this equipment. Improper
repairs could create conditions that are hazardous.
IMPORTANT: The installation of options and servicing of this product shall be performed by individuals
who are knowledgeable of the procedures, precautions, and hazards associated with equipment
containing hazardous energy circuits.
Symbols in Text
These symbols may be found in the text of this guide. They have the following meanings.
WARNING: Text set off in this manner indicates that failure to follow directions in the warning
could result in bodily harm or loss of life.
CAUTION: Text set off in this manner indicates that failure to follow directions could result in
damage to equipment or loss of information.
IMPORTANT: Text set off in this manner presents clarifying information or specific instructions.
NOTE: Text set off in this manner presents commentary, sidelights, or interesting points of information.
viii Compaq ProLiant 6400R Maintenance and Service Guide
Symbols on Equipment
These symbols may be located on equipment in areas where hazardous conditions may exist.
This symbol in conjunction with any of the following symbols indicates the presence of a
potential hazard. The potential for injury exists if warnings are not observed. Consult your
documentation for specific details.
This symbol indicates the presence of hazardous energy circuits or electric shock hazards.
Refer all servicing to qualified personnel.
WARNING: To reduce the risk of injury from electric shock hazards, do not open this
enclosure. Refer all maintenance, upgrades, and servicing to qualified personnel.
This symbol indicates the presence of electric shock hazards. The area contains no user or
field serviceable parts. Do not open for any reason.
WARNING: To reduce the risk of injury from electric shock hazards, do not open this
enclosure.
This symbol on an RJ-45 receptacle indicates a Network Interface Connection.
WARNING: To reduce the risk of electric shock, fire, or damage to the equipment, do not
plug telephone or telecommunications connectors into this receptacle.
This symbol indicates the presence of a hot surface or hot component. If this surface is
contacted, the potential for injury exists.
WARNING: To reduce the risk of injury from a hot component, allow the surface to cool
before touching.
These symbols on power supplies or systems indicate the equipment is supplied
by multiple sources of power.
WARNING: To reduce the risk of injury from electric shock, remove all power
cords to completely disconnect power from the system.
34 kg
75 lb
This symbol indicates that the component exceeds the recommended weight for one
individual to handle safely.
WARNING: To reduce the risk of personal injury or damage to the equipment, observe local
occupational health and safety requirements and guidelines for manual material handling.
About This Guide ix
Compaq Technician Notes
WARNING: Only authorized technicians trained by Compaq should attempt to repair this
equipment. All troubleshooting and repair procedures are detailed to allow only
subassembly/module level repair. Because of the complexity of the individual boards and
subassemblies, no one should attempt to make repairs at the component level or to make
modifications to any printed wiring board. Improper repairs can create a safety hazard. Any
indications of component replacement or printed wiring board modifications may void any
warranty.
WARNING: To reduce the risk of personal injury from electrical shock and hazardous energy
levels, do not exceed the level of repair specified in these procedures. Because of the
complexity of the individual boards and subassemblies, do not attempt to make repairs at the
component level or to make modifications to any printed wiring board. Improper repairs could
create conditions that are hazardous.
WARNING: To reduce the risk of electric shock or damage to the equipment:
■ If the system has multiple power supplies, disconnect power from the system by
unplugging all power cords from the power supplies.
■ Do not disable the power cord grounding plug. The grounding plug is an important safety
feature.
■ Plug the power cord into a grounded (earthed) electrical outlet that is easily accessible at
all times.
CAUTION: To properly ventilate your system, you must provide at least 12 inches (30.5 cm) of
clearance at the front and back of the computer.
CAUTION: The computer is designed to be electrically grounded. To ensure proper operation,
plug the AC power cord into a properly grounded AC outlet only.
Where to Go for Additional Help
In addition to this guide, the following information sources are available:
■ User Documentation
■ Compaq Service Quick Reference Guide
■ Service Training Guides
■ Compaq Service Advisories and Bulletins
■ Compaq QuickFind
■ Compaq Insight Manager
■ Compaq Download Facility: Call 1-281-518-1418
x Compaq ProLiant 6400R Maintenance and Service Guide
Integrated Management Display
Some Compaq server models include a Compaq Integrated Management Display (IMD), an
integrated, 16x4 character display mounted on the front of the server. This display provides
easy-to-use menu-driven access to server information, including model number, LCD firmware
revision, and POST operations.
Telephone Numbers
For the name of your nearest Compaq authorized reseller:
■ In the United States, call 1-800-345-1518
■ In Canada, call 1-800-263-5868
For Compaq technical support:
■ In the United States and Canada, call 1-800-386-2172
■ For Compaq technical support phone numbers outside the United States and Canada, visit
the Compaq website:
http://www.compaq.com
Chapter 1
Illustrated Parts Catalog
This chapter provides the illustrated parts and a spare parts list for Compaq ProLiant™ 6400R
servers. See Tables 1-1 and 1-2 for the names of referenced spare parts.
1-2 Compaq ProLiant 6400R Maintenance and Service Guide
Mechanical Parts Exploded View
1
2
3
4a
4b
Figure 1-1. Exploded view of the Compaq ProLiant 6400R server mechanical parts
Illustrated Parts Catalog 1-3
Mechanical Spare Parts List
Table 1-1
Mechanical Spare Parts List
Ref Description Spares Part #
CHASSIS
1 Chassis with Ultra2 drive cage 176668-001
2 Top access panel 101922-001
3 PCI Hot Plug basket insulator 387886-001
MISCELLANEOUS
4 Miscellaneous hardware kit 122634-001
a) Front bezel
b) Side access panel
1-4 Compaq ProLiant 6400R Maintenance and Service Guide
System Components Exploded View
3
20
8a 9a
8b 9b
8c 9c
18
2
16
14
23
24
11
10a10b
12
19
13
7
15
5
6
17
1
4
Figure 1-2. Exploded view of the Compaq ProLiant 6400R server system components
Illustrated Parts Catalog 1-5
System Components Spare Parts List
Table 1-2
System Components Spare Parts List
Ref Description Spares Part #
CHASSIS
1 Chassis 176668-001
ASSEMBLIES
2 Hot-plug dual redundant CPU fan #3 and #4 101931-001
3 Hot-plug I/O fan (2 per system) #1 and #2 101933-001
4 External rear hot-plug redundant system fan assemblies #5 and #6 158608-001
SYSTEM COMPONENTS
5
Power supply, 450 W, hot-plug 101920-001
6 Power switch and LED 101976-001
7 Replacement battery, peripheral board 179322-001
8a
500-MHz/100 Xeon (512-K) processor with heat sink 116313-001
8b
500-MHz/100 Xeon (1-MB) processor with heat sink * 122636-001
8c
500-MHz/100 Xeon (2-MB) processor with heat sink * 122637-001
9a 550-MHz/100 Xeon (512-K) processor with heat sink * 122635-001
9b 550-MHz/100 Xeon (1-MB) processor with heat sink * 122639-001
9c 550-MHz/100 Xeon (2-MB) processor with heat sink * 122640-001
10a Non-redundant Processor Power Module 328701-001
10b Redundant Processor Power Module * 328842-001
11 Processor terminator module 329271-001
* Not shown
continued
1-6 Compaq ProLiant 6400R Maintenance and Service Guide
Table 1-2
System Components Spare Parts List
continued
Ref Description Spares Part #
BOARDS
12
Memory board 328703-001
13 Peripheral board 328844-001
14 Ultra2 SCSI simplex board 387090-001
15 Power backplane board with tray 101973-001
16 CD-ROM drive adapter board 101927-001
17 System board and tray 123888-001
18 PCI Hot Plug switch/LED board and cable 328835-001
19 Dual Port PCI Netelligent 10/100 I-Base (NIC) 338478-001
MEMORY
20
64-MB dual inline memory module (buffered ECC, EDO 50 ns) 330739-001
21
128-MB dual inline memory module (buffered ECC, EDO 50 ns) * 330740-001
22
256-MB dual inline memory module (buffered ECC, EDO 50 ns) * 330741-001
MEDIA STORAGE DEVICES
23 24X Max low-profile CD-ROM drive 128400-001
24 1.44-MB diskette drive 288456-001
* Not shown
continued
Illustrated Parts Catalog 1-7
Table 1-2
System Components Spare Parts List
continued
Ref Description Spares Part #
MISCELLANEOUS
25 Miscellaneous power cable kit * 101952-001
a) CD/LVD power cable assembly
b) 10-position power cable assembly
c) 12-position power cable assembly
d) Hard drive power cable assembly
e) Left cable fan assembly 1
f) Left cable fan assembly 2
g) Right cable fan assembly
h) Rear cable fan assembly
26 Miscellaneous signal cable kit * 101953-001
a) PCI cable assembly
b) Diskette drive cable assembly
c) Miscellaneous signal cable assembly
d) CD-ROM drive signal cable assembly
e) LVD signal cable assembly
f) 26-pin power sensor cable assembly
g) PCI Hot Plug cable assembly
27 Diskette drive signal extension cable kit * 169038-001
28 Miscellaneous hardware kit * 122634-001
a) Front bezel (shown as item 4a in ”Mechanical Spare Parts List”)
b) Side access panel (shown as item 4b in ”Mechanical Spare Parts List”)
29 PCI slot cover * 271918-001
30a Return kit * 161500-001
30b Return kit ** 122645-001
31 Carton and buns (international) * 122645-002
32 Maintenance and service guide * 101978-001
33 Illustrated parts map * 101977-002
OPTIONS
34 Power supply blank cover * 122641-001
* Not shown
** For earlier 500-MHz models of the ProLiant 6400R server with a single rear CPU fan, instead of the external rear system
fan assembly
Chapter 2
Removal and Replacement Procedures
This chapter provides subassembly and module-level removal and replacement procedures for
Compaq ProLiant 6400R servers, and unless otherwise specified, the procedures apply to
ProLiant 6400R servers containing 500- or 550-MHz processors. After completing all necessary
removal and replacement procedures, run the Diagnostics program to verify that all components
operate properly.
To service ProLiant 6400R servers, you might need the following:
■ Torx T-15 screwdriver
■ 4-mm flat-blade screwdriver
■ Phillips screwdriver
■ Wire cutters
■ From the Compaq SmartStart and Support Software CD:
G System Configuration Utility software
G Drive Array Advanced Diagnostics (DAAD) software
G Diagnostics software
Electrostatic Discharge Information
A discharge of static electricity can damage static-sensitive devices or microcircuitry. Proper
packaging and grounding techniques are necessary precautions to prevent damage. To prevent
electrostatic damage,
■ 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 workstations with approved static-dissipating material. Provide a wrist strap
connected to the work surface and properly grounded tools and equipment.
■ Keep the work area free of nonconductive materials, such as ordinary plastic assembly
aids and foam packing.
■ Always be properly grounded when touching a static-sensitive component or assembly.
■ Avoid touching pins, leads, or circuitry.
2-2 Compaq ProLiant 6400R Maintenance and Service Guide
■ Always place drives, printed circuit boards (PCB) assembly-side down.
■ Use conductive field service tools.
Symbols on Equipment
These symbols may be located on equipment in areas where hazardous conditions may exist.
This symbol in conjunction with any of the following symbols indicates the presence of a
potential hazard. The potential for injury exists if warnings are not observed. Consult your
documentation for specific details.
This symbol indicates the presence of hazardous energy circuits or electric shock hazards.
Refer all servicing to qualified personnel.
WARNING: To reduce the risk of injury from electric shock hazards, do not open this
enclosure. Refer all maintenance, upgrades, and servicing to qualified personnel.
This symbol indicates the presence of electric shock hazards. The area contains no user or
field serviceable parts. Do not open for any reason.
WARNING: To reduce the risk of injury from electric shock hazards, do not open this
enclosure.
This symbol on an RJ-45 receptacle indicates a Network Interface Connection.
WARNING: To reduce the risk of electric shock, fire, or damage to the equipment, do not
plug telephone or telecommunications connectors into this receptacle.
This symbol indicates the presence of a hot surface or hot component. If this surface is
contacted, the potential for injury exists.
WARNING: To reduce the risk of injury from a hot component, allow the surface to cool
before touching.
These symbols on power supplies or systems indicate the equipment is supplied
by multiple sources of power.
WARNING: To reduce the risk of injury from electric shock, remove all power
cords to completely disconnect power from the system.
34 kg
75 lb
This symbol indicates that the component exceeds the recommended weight for one
individual to handle safely.
WARNING: To reduce the risk of personal injury or damage to the equipment, observe local
occupational health and safety requirements and guidelines for manual material handling.
Removal and Replacement Procedures 2-3
Preparation Procedures
Hot-Pluggable Components
Before the removal of any serviceable part, determine whether it is hot-pluggable or
non-hot-pluggable. If it is hot-pluggable, do not perform a power shutdown of the server. The
access panels can be removed while the server is turned on without system shutdown. When the
server is in Standby mode, portions of the power supply, auxiliary power (+5V), and some
internal circuitry remain active.
Non-Hot-Pluggable Components
If the part is non-hot-pluggable, shut down the server. Non-hot-pluggable parts include the
processor, Processor Power Module, system board, memory board, Dual Inline Memory
Modules (DIMMs), peripheral board, and modem. Refer to “Powering Down the Server” later
in this chapter for complete power-down instructions.
WARNING: To reduce the risk of injury from electric shock, remove all power
cords to completely disconnect power from the system.
Powering Down the Server
System power in the ProLiant 6400R Server does not completely shut off with the front panel
Power On/Standby switch. The two positions of the switch function as On and Standby, rather
than On and Off. The Standby position removes power from most of the electronics and the
drives, but portions of the power supply and some internal circuitry remain active.
IMPORTANT: To completely remove all power from the system, you must disconnect the power cord
from the server. In systems with multiple power supplies, you must disconnect all the power cords to
completely remove power from the system.
IMPORTANT: It is not necessary to turn off the server to replace hot-plug devices such as power
supplies, fans, or PCI Hot Plug boards.
Before beginning any of the removal and replacement procedures for non-hot-plug devices,
1. Move the Power On/Standby switch to the Standby position.
2. Disconnect the AC power cord from the AC outlet and then from the server.
3. Disconnect all external peripheral devices from the server.
For some removal and replacement procedures, you must remove the server from the rack and
place it on a sturdy table or workbench. Refer to the ProLiant 6400R Setup and Installation
Guide for instructions.
/
