Document fcos/A0173-1
FCO #: A0173-1
SYNOPSIS: Ultra 5 and Ultra 10 systems with Sapphire Red Modules have shown an
increase in early life failures
DATE: Jun/19/2001
KEYWORDS: Ultra 5 and Ultra 10 systems with Sapphire Red Modules have shown an
increase in early life failures
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- Sun Proprietary/Confidential: Internal Use Only -
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FIELD CHANGE ORDER
(For Authorized Distribution by SunService)
SYNOPSIS: Ultra 5 and Ultra 10 systems with Sapphire Red Modules
have shown an increase in early life failures.
Sun Alert: N
TOP FIN/FCO REPORT: Yes
PRODUCT_REFERENCE: Sapphire Red CPU Modules 360/400/440MHz
PRODUCT CATEGORY: DeskTop / System CPU Module
PRODUCT AFFECTED:
Mkt_ID Platform Model Description Serial Number
------ -------- ----- ----------- -------------
Systems Affected:
------- --------
- A22 - 360/400/440MHz Ultra 10 xx030xxxxx - xx048xxxxx
- A21 - 360/400/440MHz Ultra 5 xx030xxxxx - xx048xxxxx
- SPARCEngine UltraAXi Motherboard CPU xx030xxxxx - xx048xxxxx
X-Options Affected
--------- -------
X2754A E10000 - E10000 System Service Processor xx030xxxxx - xx048xxxxx
AFFECTED PARTS:
Part Number Description Model
----------- ----------- -----
501-5741-01 CPU Module SR 400MHz 2MB -
501-5148-06 CPU Module SR 360MHz .25MB -
501-5149-08 CPU Module SR 440MHz 2MB -
(SCSI Devices)
Type Vendor Model SerialNumber(Min) SerialNumber(Max) Firmware
---- ------ ------- ------------------ ------------------ --------
N/A
REFERENCES :
WWStopShip: WSS001#03700
DPCO: 226: Rework all AT&S FABs (Apr/12/01)
DPCO: 215: Purge and Hold all AT&S FABs (Feb/09/01)
DPCO: 271.A EMEA & APAC Returns
PROBLEM DESCRIPTION :
There has been a recent increase in early life failure rates on Ultra 10 and
Ultra 5 systems containing 360MHz, 400MHz, and 440MHz (Sapphire Red) CPU
Modules shipped between week 30 through week 48. Only CPU modules
manufactured with one specific FAB are affected. The affected system serial
number range is xx030xxxxx to xx048xxxxx.
The Primary symptoms associated with the affected modules are as follows;
- system hang/lockup
- drops to ok prompt
- spontaneous reboots
In some instances, you may also see CPU Panic, panic errors or system panic
bad trap.
The root cause of this early life failure is related to a vendor manufacturing
process which resulted in dry film mask contamination on the pads. Out of
approximately 135,000 Sapphire Red modules shipped between week 30 and 48 of
year 2000, it is estimated that about 45,000 are from the AFFECTED FAB in
question. No other FABs are affected by this issue.
Corrective action was implemented within Sun Manufacturing via Worldwide
StopShip/Purge WSS001#03700 on December 31, 2000. Corrective action was
implemented within Enterprise Services via DPCO# 215 as of February 9, 2001.
A rework process was implemented via DPCO# 226 as of April 12, 2001.
Good modules can be identified as NONAFFECTED FAB by having "DPCO
215"label
on the FRU packaging. Reworked modules from the affected FAB will have a
"DPCO 226A" or "DPCO 226B" label. Reference the Corrective
Action section
for more information.
If needed an end-user Customer Letter has been developed and can be accessed
via
the below URLs in either postscript or StarOffice versions;
http://sdpsweb.EBay/FIN_FCO/FCO/FCO_A0173-1_Dir/Customer_Letter.ps
http://sdpsweb.EBay/FIN_FCO/FCO/FCO_A0173-1_Dir/Customer_Letter.sdw
IMPLEMENTATION :
---
| | MANDATORY (Fully Pro-Active)
---
---
| | CONTROLLED PRO-ACTIVE (per Sun Geo Plan)
---
---
| X | UPON FAILURE (As Required)
---
REPLACEMENT TIME ESTIMATE : 0.5 hours
SPECIAL CONSIDERATION :
Because the final Root Cause has determined this to be an Early Life issue,
systems running more than 72 hours are at little, if any, risk of experiencing
this problem. Therefore, Sun recommends NOT replacing modules in these
mature systems if no failure has been experienced, as this will only cause
unnecessary customer down time and may induce a problem in an otherwise
running system.
CORRECTIVE ACTION :
Upon failure replace AT&S FABs as follows;
501-5149-08 (or below) with 501-5149-08 (or above) having a "DPCO
226A"
or "DPCO 226B" label, or having a "WSS001#03700"
label, or
with a NONAFFECTED FAB.
501-5148-06 (or below) with 501-5148-06 (or above) having a "DPCO
226A"
or "DPCO 226B" label, or having a "WSS001#03700"
label, or
with a NONAFFECTED FAB.
501-5741-01 with 501-5741-01 (or above) (or above) having a "DPCO
226A"
or "DPCO 226B" label, or having a "WSS001#03700"
label, or
with a NONAFFECTED FAB.
*** CAUTION! TO AVOID ANY MODULE DAMAGE refer to the following CPU module
handling document;
http://sdpsweb.EBay/FIN_FCO/FCO/FCO_A0173-1_Dir/IIi.Module.Handling
For detailed system inspection and replacement procedures refer to the
"Sun Ultra 5 and Ultra 10 CPU Module Inspection and Replacement Guide";
http://acts.ebay/ready/u5_u10/U5-U10-rework.pdf
To identify a suspect module:
1. Check the system to see if it falls in the serial number range.
2. Check the module to see if it is an AT&S fab per the inspection
guidelines set forth below.
For detailed instructions please see below pdf file:
http://sdpsweb.ebay/FIN_FCO/FCO/FCO_A0173-1_Dir/ModuleInspection.pdf
COMMENTS :
For information on previous field communications on this subject reference
the following URLs;
http://onestop/hw/u5.shtml
http://onestop/hw/u10.shtml
BILLING TYPE:
Warranty: Sun will provide parts at no charge under Warranty
Service. On-Site Labor Rates are based on how the
system was initially installed.
Contract: Sun will provide parts at no charge. On-Site Labor Rates
are based on the type of service contract.
Non Contract: Sun will provide parts at no charge. Installation by
Sun is available based on the On-Site Labor Rates
defined in the Price List.
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Implementation Footnote:
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i) In case of Mandatory FCOs, Enterprise Services will attempt to contact
all known customers to recommend the part upgrade.
ii) For controlled proactive swap FCOs, Enterprise Services mission critical
support teams will initiate proactive swap efforts for their respective
accounts, as required.
iii) For Replace upon Failure FCOs, Enterprise Services partners will implement
the necessary corrective actions as and when they are required.
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